WARNING.

fm 1 ページ ２００６年９月２２日　金曜日　午後５時１０分

WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Mazda-trained technicians in mind. This manual may be useful to
non-Mazda trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks

not normally encountered in a general technician's experience.
They should be followed to reduce the risk of injury and the risk
that improper service or repair may damage the vehicle or render it
unsafe. It is also important to understand that the "Warnings" and
"Cautions" are not exhaustive. It is impossible to warn of all
the hazardous consequences that might result from failure to follow
the procedures.

The procedures recommended and described in this manual are

effective methods of performing service and repair. Some require tools
specifically designed for a specific purpose. Persons using procedures
and tools which are not recommended by Mazda Motor Corporation
must satisfy themselves thoroughly that neither personal safety nor
safety of the vehicle will be jeopardized.

The contents of this manual, including drawings and specifications, are

the latest available at the time of printing, and Mazda Motor Corporation
reserves the right to change the vehicle designs and alter the contents
of this manual without notice and without incurring obligation.

Parts should be replaced with genuine Mazda replacement parts or

with parts which match the quality of genuine Mazda replacement
parts. Persons using replacement parts of lesser quality than that of
genuine Mazda replacement parts must satisfy themselves thoroughly
that neither personal safety nor safety of the vehicle will be
jeopardized.

Mazda Motor Corporation is not responsible for any problems which

may arise from the use of this manual. The cause of such problems
includes but is not limited to insufficient service-related training, use of
improper tools, use of replacement parts of lesser quality than that of
genuine Mazda replacement parts, or not being aware of any revision
of this manual.
1890-1U-06L(INDEX).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時４８分

2007 CONTENTS
Mazda Title Section

CX-9 GENERAL INFORMATION 00

Workshop ENGINE 01

Manual SUSPENSION 02

FOREWORD DRIVELINE/AXLE 03
This manual contains on-vehicle service
and/or diagnosis procedures for the Mazda BRAKES 04
CX-9.
TRANSMISSION/TRANSAXLE 05
For proper repair and maintenance,
a thorough familiarization with this manual is STEERING 06
important, and it should always be kept in a
handy place for quick and easy reference. HEATER, VENTILATION & 07
AIR CONDITIONING (HVAC)
All the contents of this manual, including
drawings and specifications, are the latest RESTRAINTS 08
available at the time of printing.
As modifications affecting repair or BODY & ACCESSORIES 09
maintenance occur, relevant information
supplementary to this volume will be made ALPHABETICAL INDEX AI
available at Mazda dealers. This manual
should be kept up-to-date. © 2006 Mazda Motor Corporation
PRINTED IN U.S.A., DECEMBER 2006
Mazda Motor Corporation reserves the right Form No. 1890–1U–06L
to alter the specifications and contents of Part No. 9999–95–003B–07
this manual without obligation or advance
notice.

All rights reserved. No part of this book may

be reproduced or used in any form or by any
means, electronic or mechanical—including
photocopying and recording and the use of
any kind of information storage and retrieval
system—without permission in writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials
shown on the following page.
1890-1U-06L(INDEX).fm 2 ページ ２００６年１２月１９日　火曜日　午後１２時４８分

VEHICLE IDENTIFICATION NUMBERS (VIN)

JM3 TB28C✻7# 100001—

JM3 TB28Y✻7# 100001—
JM3 TB38C✻7# 100001—
JM3 TB38Y✻7# 100001—

RELATED MATERIALS

Material Name MNAO Part No. Mazda Material No.

2007 Mazda CX-9 Service Highlights 9999–95–001F–07 3423–1U–06L

Automatic Transaxle and Transfer Workshop Manual

9999–95–0AW6–07 1874–1U–06B
AW6A-EL AW6AX-EL

2007 Mazda CX-9 Bodyshop Manual 9999–95–007F–07 3424–1U–06L

2007 Mazda CX-9 Wiring Diagram 9999–95–009G–07 5681–1U–06K

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)

GENERAL INFORMATION 00SECTION

00-00

Toc of SCT INFORMATION . . . . 00-00

GENERAL
Toc of SCT
00-00 GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER INSTALLATION OF RADIO
(VIN) CODE . . . . . . . . . . . . . . . . . . . . . . 00-00–2 SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 00-00–19
VEHICLE IDENTIFICATION NUMBER ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00-00–20
(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–2 Electrical Parts . . . . . . . . . . . . . . . . . . . 00-00–20
HOW TO USE THIS MANUAL . . . . . . . . . 00-00–3 Wiring Harness. . . . . . . . . . . . . . . . . . . 00-00–20
Range of Topics . . . . . . . . . . . . . . . . . . 00-00–3 Connectors . . . . . . . . . . . . . . . . . . . . . . 00-00–20
Service Procedure . . . . . . . . . . . . . . . . 00-00–3 Terminals . . . . . . . . . . . . . . . . . . . . . . . 00-00–22
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–5 Sensors, Switches, and Relays . . . . . . 00-00–23
Advisory Messages. . . . . . . . . . . . . . . . 00-00–5 Wiring Harness. . . . . . . . . . . . . . . . . . . 00-00–23
Troubleshooting Procedure . . . . . . . . . . 00-00–6 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–23
Procedures for Use . . . . . . . . . . . . . . . . 00-00–7 Viewing orientation for
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–12 Connectors . . . . . . . . . . . . . . . . . . . . . 00-00–24
Conversion to SI Units (Système Electrical Troubleshooting
International d'Unités) . . . . . . . . . . . . . 00-00–12 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–25
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00-00–12 Precautions Before Welding . . . . . . . . . 00-00–26
Upper and Lower Limits . . . . . . . . . . . . 00-00–12 JACKING POSITIONS, VEHICLE LIFT
SERVICE CAUTIONS . . . . . . . . . . . . . . . . 00-00–13 (2 SUPPORTS) AND SAFETY STAND
Injury/damage Prevention (RIGID RACK) POSITIONS . . . . . . . . . . 00-00–27
Precautions . . . . . . . . . . . . . . . . . . . . . 00-00–13 Jacking Positions . . . . . . . . . . . . . . . . . 00-00–27
Protection of the Vehicle . . . . . . . . . . . . 00-00–13 Vehicle Lift Positions. . . . . . . . . . . . . . . 00-00–28
Preparation of Tools and Measuring Safety Stand Positions . . . . . . . . . . . . . 00-00–28
Equipment . . . . . . . . . . . . . . . . . . . . . . 00-00–13 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–29
Special Service Tools . . . . . . . . . . . . . . 00-00–13 Tiedown Hooks. . . . . . . . . . . . . . . . . . . 00-00–30
Malfunction Diagnosis System . . . . . . . 00-00–13 TIEDOWN HOOK. . . . . . . . . . . . . . . . . . . 00-00–31
Disconnection of the Negative IDENTIFICATION NUMBER
Battery Cable . . . . . . . . . . . . . . . . . . . 00-00–14 LOCATIONS . . . . . . . . . . . . . . . . . . . . . 00-00–32
Oil Leakage Inspection . . . . . . . . . . . . . 00-00–14 Vehicle Identification
Removal of Parts. . . . . . . . . . . . . . . . . . 00-00–14 Number (VIN) . . . . . . . . . . . . . . . . . . . 00-00–32
Disassembly . . . . . . . . . . . . . . . . . . . . . 00-00–15 Engine Identification Number . . . . . . . . 00-00–32
Inspection During Removal, SAE STANDARDS. . . . . . . . . . . . . . . . . . 00-00–32
Disassembly . . . . . . . . . . . . . . . . . . . . 00-00–15 ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00-00–33
Arrangement of Parts . . . . . . . . . . . . . . 00-00–15 PRE-DELIVERY INSPECTION . . . . . . . . 00-00–34
Cleaning of Parts. . . . . . . . . . . . . . . . . . 00-00–15 Pre-Delivery Inspection Table. . . . . . . . 00-00–34
Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–16 SCHEDULED MAINTENANCE . . . . . . . . 00-00–36
Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–16 Scheduled Maintenance Table for
Rubber Parts and Tubing . . . . . . . . . . . 00-00–16 U.S.A., CANADA and
Hose Clamps. . . . . . . . . . . . . . . . . . . . . 00-00–17 Puerto Rico . . . . . . . . . . . . . . . . . . . . 00-00–36
Torque Formulas . . . . . . . . . . . . . . . . . . 00-00–17 Scheduled Maintenance
Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–17 Table for Mexico . . . . . . . . . . . . . . . . . 00-00–39
Dynamometer . . . . . . . . . . . . . . . . . . . . 00-00–17
HANDLING SPARE TIRE . . . . . . . . . . . . 00-00–42
AWD inspection/service . . . . . . . . . . . . 00-00–18
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–19 Remove The Spare Tire . . . . . . . . . . . 00-00–42
Install The Spare Tire . . . . . . . . . . . . . 00-00–43

End of Toc
NG: GENERAL INFORMATION

Added 1/2007 (Ref. No. R009/07) 00-00–1

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
id000000100200

J M3 TB28C* 7# 12 3 4 5 6
Serial No.

0= Hiroshima
Plant 1= Hofu

Model year 7= 2007

Check digit *= 0 to 9, X

C= 3.5 L, MZI-3.5 (California)

Engine Y= 3.5 L, MZI-3.5 (Federal/CANADA)

Body 8= Multi-purpose vehicle (Wagon)

3= AWD
Chassis type 2= 2WD

Carline, Series TB= Mazda CX-9

World manufacturer identification JM3= Mazda (Multi-purpose vehicle category)

ac9uuw00001184

End Of Sie
VEHICLE IDENTIFICATION NUMBER (VIN)
id000000100300
JM3 TB28C*7# 100001—
JM3 TB28Y*7# 100001—
JM3 TB38C*7# 100001—
JM3 TB38Y*7# 100001—
End Of Sie
WM: GENERAL INFORMATION

00-00–2
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GENERAL INFORMATION
HOW TO USE THIS MANUAL
id000000800100
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation 00-00
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.

Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}

49 1232 670A

49 H002 671 SHOWS TIGHTENING

TORQUE
49 H032 322 SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.

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00-00–3
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GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S)
INDICATES RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES THAT NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal)
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION

GREASE
FOR SERVICE 12 SST R

INSTALL THE PARTS BY SHOWS APPLICATION

PERFORMING STEPS 8 43—56 {4.3—5.8, 32—41}
POINTS OF GREASE, ETC.
10
1— 3 IN REVERSE ORDER 44—60 {4.4—6.2, 32—44} 7 R

SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS EXPENDABLE PARTS

SST
3
5
6 SHOWS DETAILS
SST
GREASE

4 R
94—116 {9.5—11.9, 69—86}
2 118—156 {12.0—16.0, 87—115}
SHOWS TIGHTENING
1 R TORQUE UNITS
SHOWS REFERRAL
NOTES FOR SERVICE N·m {kgf·m, ft·lbf}

1 Split pin 7 Split pin

2 Nut 8 Nut
3 Lower trailing link ball joint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)

Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.

SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE

49 T028 303

SHOWS REFERRAL
NOTES FOR
SERVICE
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GENERAL INFORMATION
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. use. These
symbols show application points or use of these materials during service.
Symbol Meaning Kind
00-00
New appropriate
OIL Apply oil engine oil or gear
oil

New appropriate
BRAKE Apply brake fluid
FLUID brake fluid

New appropriate
Apply automatic
automatic
transaxle/
ATF
transaxle/
transmission fluid
transmission fluid

Appropriate
Apply grease
GREASE

grease

Appropriate
SEALANT Apply sealant
sealant

Apply petroleum Appropriate

P jelly petroleum jelly

O-ring, gasket,
R Replace part
etc.

Use SST or
SST equivalent
Appropriate tools

Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.

Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

Note
• A Note provides added information that will help you to complete a particular procedure.

Specification
• The values indicate the allowable range when performing inspections or adjustments.

Upper and lower limits

• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.

00-00–5
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GENERAL INFORMATION
Troubleshooting Procedure
Basic flow of troubleshooting

CUSTOMER ARRIVES

WARNING LIGHT* NO WARNING LIGHT*

ON/FLASHING WITH SYMPTOM

CHECK FOR CHECK DTC

PRIORITIZED DTC IGNITION ON TEST, IDLING
TEST
DTC

WITHOUT DTC

DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC) DIAGNOSE BY SYMPTOM
DTC TABLE (SYMPTOM TROUBLESHOOTING)
DTC 1. DIAGNOSTIC INDEX
TROUBLESHOOTING 2. QUICK DIAGNOSIS CHART
FLOW (IF MENTIONED)
3. SYMPTOM
*: INDICATOR LIGHTS AND WARNING TROUBLESHOOTING
LIGHTS THAT INDICATE MALFUNCTIONS

acxuuw00000444

DTC troubleshooting flow (on-board diagnostic)

• Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate.
Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction.
• The on-board diagnostic function is used during inspection. When a DTC is shown specifying the cause of a
malfunction, continue the diagnostic inspection according to the items indicated by the on-board diagnostic
function.

Diagnostic index
• The diagnostic index lists the symptoms of specific malfunctions. Select the symptoms related or most closely
relating to the malfunction.

Quick diagnosis chart (If mentioned)

• The quick diagnosis chart lists diagnosis and inspection procedures to be performed specifically relating to the
cause of the malfunction.

Symptom troubleshooting
• Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.

00-00–6
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GENERAL INFORMATION
Procedures for Use
Using the basic inspection (section 05)
• Perform the basic inspection procedure before symptom troubleshooting.
• Perform each step in the order shown.
• The reference column lists the location of the detailed procedure for each basic inspection.
• Although inspections and adjustments are performed according to the reference column procedures, if the 00-00
cause of the malfunction is discovered during basic inspection, continue the procedures as indicated in the
action column.
SHOWS INSPECTION SHOW POINTS REQUIRING
SHOWS ITEM NAMES FOR
ORDER ATTENTION BASED ON
DETAILED PROCEDURES
INSPECTION RESULTS
BASIC INSPECTION

STEP INSPECTION ACTION

1 Perform the mechanical system test. Yes Go to the next step.
(See 05-13-3 MECHANICAL SYSTEM TEST.) No Repair or replace any malfunctioning parts according to
Is mechanical system normal? the inspection result.
2 Turn the ignition switch to the ON position. Yes Go to next step.
When the selector lever is moved, does the selector No Inspect the selector lever and TR switch. Repair or
illumination indicate synchronized position to the replace malfunctioning parts.
lever location? Also, when other ranges are selected (See 05-14-5 SELECTOR LEVER INSPECTION.)
from N or P during idling, does the vehicle move (See 05-13-10 TRANSMISSION RANGE (TR) SWITCH
within 1—2 s? INSPECTION.)
If the selector lever and TR switch are normal, go to the
next step.
3 Inspect the ATF color condition. Yes Go to the next step.
(See 05-13-8 AUTOMATIC TRANSMISSION No Repair or replace any malfunctioning parts according to
FLUID (ATF) INSPECTION.) the inspection result.
Are ATF color and odor normal? Flush ATX and cooler line as necessary.
4 Perform the line pressure test. Yes Go to the next step.
(See 05-13-3 Line Pressure Test.) No Repair or replace any malfunctioning parts according to
Is the line pressure normal? the inspection result.
5 Perform the stall test. Yes Go to the next step.
REFERENCE (See 05-13-4 Stall Speed Test.) No Repair or replace any malfunctioning parts according to
Is the stall speed normal? the inspection result.
COLUMN
Yes Go to the next step.
Inspect the voltage at the following TCM terminals.
(See 05-13-29 TCM INSPECTION.) No Repair or replace any malfunctioning parts according to
the inspection result.
Terminal 2J (TFT sensor)
Terminals 1D, 2B, 2C, 2E (TR switch)
Terminal 2G (turbine sensor)
Terminal 2D (down switch)
Terminal 2I (up switch)
Terminal 1E (M range switch)
Terminal 1W (steering shift switch)
Is the voltage normal?

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00-00–7
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GENERAL INFORMATION
Using the DTC troubleshooting flow
• DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each
DTC.

DETECTION CONDITION
describes the condition
TROUBLE CONDITION under which the DTC is
detected.
DTC P0103
DTC PO103 MAF circuit high input
PCM monitors input voltage from TP sensor after ignition key is turned on. If input voltage at PCM terminal 68 is
above 8.25 V, PCM determines that TP circuit has malfunction.

Diagnostic support note

DETECTION
This is a continuous monitor (CCM).
CONDITION
MIL illuminates if PCM detects the above malfunction during first drive cycle. Therefore,
POSSIBLE PENDING CODE is not available.
CAUSE FREEZE FRAME DATE is available.
describes DTC is stored in the PCM memory.
MAF sensor malfunction
possible POSSIBLE
Connector or terminal malfunction
CAUSE
point(s) of Open circuit in wiring between MAF sensor terminal D and PCM terminal 36 Indicates the
malfunction Open circuit in MAF sensor ground circuit
circuit to be
FROM

MAF SENSOR
MAIN RELAY
TERMINAL D
PCM inspected
4 (01 and 05
Indicates the B
section)
inspection step 6
4 5
No. to be E 88

performed 4 6
7
(01 and 05 D 36

section)
MAF SENSOR PCM Indicates the
HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR
connector
1P related to the
E D C B A inspection

STEP shows
the order of ACTION
troubleshooting Diagnostic procedure describes the
STEP INSPECTION ACTION appropriate
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step.
RECORDED No Record FREEZE FRAME DATA on repair order, then go
action to be taken
Has FREEZE FRAME DATA been recorded? to next step. according to
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair the result
AVAILABILITY information.
Are related Service Bulletins and/or on-line
If vehicle is not repaired, then go to next step. (Yes/No) of the
repair information available? No Go to next step. INSPECTION.
3 VERIFY CURRENT INPUT SIGNAL STATUS IS Yes Intermittent concern is existing. Go to INTERMITTENT
INSPECTION CONCERN INTERMITTENT OR CONSTANT CONCERNS TROUBLESHOOTING procedure.
Connect diagnostic tool to DLC-2. (See 01-03-33 INTERMITTENT CONCERN Reference
describes the
Start engine. TROUBLESHOOTING) item(s) to
method to Access MAF V PID using diagnostic tool. No Go to next step. perform
quickly Is MAF V PID within 0.2 - 8.3 V?
4 INSPECT POOR CONNECTION OF MAF Yes Repair or replace terminals, then go to Step 8. ACTION.
determine the SENSOR CONNECTOR
malfunctioning Turn ignition key to OFF.
part(s). Disconnect MAF sensor connector.
Check for poor connection (damaged, pulled-
out terminals, corrosion etc.).
Are there any malfunctions?

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GENERAL INFORMATION
Using the diagnostic index
• Malfunction symptoms are listed in the diagnostic index under symptom troubleshooting.
• The exact malfunction symptoms can be selected by following the index.
No. TROUBLESHOOTING ITEM DESCRIPTION Page

1 Melting of main or other fuses

(See 01-03-6 MELT NO.1 MAIN OR
OTHER FUSE)
00-00
2 MIL comes on MIL is illuminated incorrectly. (See 01-03-7 NO.2 MIL COMES ON)
3 Will not crank Starter does not work. (See 01-03-8 NO. 3 WILL NOT CRANK)
Starter cranks engine at normal
Hard start/long crank/erratic start/erratic (See 01-03-9 NO. 4 HARD START/
4 speed but engine requires excessive
crank LONG CRANK/ERRATIC CRANK)
cranking time before starting.
Engine stops unexpectedly at idle (See 01-03-11 NO. 5 ENGINE-STALLS
5 Engine stalls. After start/at idle
and/or after start. AFTER START/AT IDLE)
Starter cranks engine at normal (See 01-03-15 NO.6 CRANKS
6 Cranks normally but will not start
speed but engine will not run. NORMALLY BUT WILL NOT START)
Engine takes more time than normal (See 01-03-19 NO. 7 SLOW RERUN
7 Slow return to idle
to return to idle speed. TO IDLE)
Engine speed fluctuates between
specified idle speed and lower (See 01-03-20 NO. 8 ENGINE RUNS
8 Engine runs rough/rotling
speed and engine shakes ROUGH/ROLLING IDLE )
excessively.
Engine speed continues at fast idle
after warm-up. (See 01-03-23 NO. 9 FAST IDLE/RUNS
9 Fast idle/runs on
Engine runs after ignition key is ON)
turned to OFF.
Engine stops unexpectedly at begin-
(See 01-03-24 NO. 10 LOW IDLE/
10 Low idle/stalls during deceleration ning of deceleration or recovery
STALLS DURING DECELERATION)
from deceleration.

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GENERAL INFORMATION
Using the quick diagnosis chart
• The chart lists the relation between the symptom and the cause of the malfunction.
• The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It
also specifies a range of common causes when multiple malfunction symptoms occur.
• The appropriate diagnostic inspection relating to a malfunction cause as specified by the symptoms can be
selected by looking down the diagnostic inspection column of the chart.

2 PARTS WHICH MAY BE THE

CAUSE OF PROBLEMS

SYMPTOM QUICK DIAGNOSTIC CHART

Cooling fan or condenser fan seat improperly

Possible factor

Starter circuit including ignition switch open

Accelerator cable free play mis-adjustment

hoses, overflow system, thermostat, etc.)
Water and anti-freeze mixture improperly
Starter motor malfunction (Mechanical or

Improper tension or damaged drive belts

Engine or transaxle mounts improperly

Cooling system malfunction (Radiator,

Cooling fan system malfunction

PART WHICH MAY BE

Improper engine compression

Improper engine coolant level

Drive plate or flywheel seized
Charging system malfunction

Improper engine oil viscosity

THE SYMPTOM

Base engine malfunction

Improper engine oil level

Improper valve timing

Low or dead battery

Hydrolocked engine

Improper dipstick

Fuel quality
electrical)

installed
Troubleshooting item

1 Melts of main or other fuse

2 MIL comes on
3 Will not crank X X X X X X

Hard to start/long crank/erratic start/erratic

4 X
crank
5 Engine stalls After start/at idle X X X X

6 Cranks normally but will not start X X X X

7 Slow return to idle X

8 Engine runs rough/rolling idle X X X

9 Fast idle/runs on X

10 Low idle/stalls during deceleration

Engine stalls/quits Acceleration/cruise X X X

Engine runs rough Acceleration/cruise X X X

Misses Acceleration/cruise X X X

11 Acceleration/cruise/
Buck/jerk X X X
deceleration
Hesitation/stumble Acceleration X X X

Surges Acceleration/cruise X X X

12 Lack/loss of power Acceleration/cruise X X X

13 Knocking/pinging Acceleration/cruise X X

1 CHOOSE THE 14 Poor fuel economy X X X X X X

ACTUALSYMPTOM 15 Emissions compliance X X X X

16 High oil consumption/leakage X X X

17 Cooling system concerns Overheating X X X X X

18 Cooling system concerns Runs cold X X

19 Exhaust smoke X X

20 Fuel odor (in engine compartment)

21 Engine noise X X X

22 Vibration concerns (engine) X X X

23 A/C does not work sufficiently

A/C always on/ A/C compressor runs
24
continuously
A/C does not cut off under wide open throttle
25
conditions
26 Exhaust sulphur smell X

27 Fuel refill concerns

28 Fuel filling shut off issues
29 Intermittent concerns X

30 Constant voltage
31 Spark plug condition X X X X X

Automatic transaxle Upshift/downshift/

32 (See 05-01 AUTOMATIC TRANSAXLE SYMPTOM TROUBLESOOTING)
concerns engagement

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GENERAL INFORMATION
Using the symptom troubleshooting
• Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to be taken for
each trouble symptom.

DESCRIPTION
describes what
00-00
kind of TROUBLE
SYMPTOM TROUBLE SYMPTOM
14 Engine flares up or slips when upshifting or down shifting
When accelerator pedal is depressed for driveway, engine speed increase but vehicle speed increase
DESCRIPTION slowly.
When accelerator is depressed while driving, engine speed increases but vehicle not.
There is clutch slip because clutch is stuck or line pressure is low.
Clutch stuck, slippage (forward clutch, 3-4 clutch, 2-4 brake band, one-way clutch 1, one-way clutch 2)
Line pressure low
POSSIBLE Malfunction or mis-adjustment of TP sensor
CAUSE Malfunction of VSS
Malfunction of input/turbine speed sensor
describes Malfunction of sensor ground
possible Malfunction of shift solenoid A, B or C
point of Malfunction of TCC solenoid valve
POSSIBLE Malfunction of body ground
malfunction CAUSE
Malfunction of throttle cable
Malfunction of throttle valve body
Poor operating of mechanical pressure
Selector lever position disparity
TR switch position disparity

Note
STEP shows
Before following troubleshooting steps, make sure that Automatic Transaxle On-board Diagnostic and
the order of Automatic Transaxle Basic Inspection are conducted.
troubleshooting. ACTION
Diagnostic procedure describes the
STEP INSPECTION ACTION appropriate
1 Is line pressure okay? Yes Go to next step.
action to be
No Repair or replace any defective parts according to
Reference inspection results. taken according
item(s) for 2 Is shift point okay? Yes Go to next step to the result
additional (See 05-17-5 ROAD TEST) No Go to symptom troubleshooting No.9 "Abnormal shift". (Yes/No) of the
information 3 Stop engine and turn ignition switch on. Yes Overhaul control valve body and repair or replace any INSPECTION.
Connect diagnostic tool to DLC-2. defective parts.
to perform (See ATX Workshop Manual GF4A-EL (1666-1A-99F))
INSPECTION. Simulate SHIFT A, SHIFT B and SHIFT C PIDs How to
for ON.
Is operating sound of shift solenoids heard? If problem remains, replace or overhaul transaxle and
perform
repair or replace defective parts. ACTION is
(See 05-17-15 AUTOMATIC TRANSAXLE described in
INSPECTION REMOVEVAL/INSTALLATION)
describes the the relative
method to material
No Inspect for bend, damage, corrosion or loose shown.
quickly connection if shift solenoid A, B, or C terminal on ATX.
determine the Inspect for shift solenoid mechanical stuck.
malfunctioning (See 05-17-14 Inspection of Operation)
If shift solenoids are okay, inspect for open or short Reference
part(s). circuit between PCM connector terminal A, B or C. item(s) to
4 Verify test results.
perform
If okay, return to diagnostic index to service any additional symptoms.
If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair or
ACTION.
diagnosis.
If vehicle is repaired, troubleshooting completed.
If vehicle is not repaired or additional diagnostic information is not available, replace or reprogram PCM.

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End Of Sie

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GENERAL INFORMATION
UNITS
id000000801600

Electrical current A (ampere)

Electric power W (watt)
Electric resistance ohm
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)

Positive pressure kgf/cm2 (kilogram force per square

centimeter)
psi (pounds per square inch)
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)

Conversion to SI Units (Système International d'Unités)

• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.

Rounding Off
• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

Upper and Lower Limits

• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit, and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:

210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}

• The actual converted values for 2.7 kgf/cm2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie

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GENERAL INFORMATION
SERVICE CAUTIONS
id000000800200
Injury/damage Prevention Precautions
• Depending on the vehicle, the cooling fan may operate suddenly even when the ignition switch is turned off.
Therefore, keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent
injury to personnel or damage to the cooling fan. Always disconnect the negative battery cable when servicing 00-00
the cooling fan or parts near the cooling fan.

Protection of the Vehicle

• Always be sure to cover fenders, seats and floor
areas before starting work.

acxuuw00000005

Preparation of Tools and Measuring Equipment

• Be sure that all necessary tools and measuring
equipment are available before starting any work.

acxuuw00000006

Special Service Tools

• Use special service tools or the equivalent when
they are required. 49 SE01 310

acxuuw00002395

Malfunction Diagnosis System

• Use the Mazda modular diagnostic system (M-MDS) for malfunction diagnosis.

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GENERAL INFORMATION
Disconnection of the Negative Battery Cable
• When working with the negative battery cable disconnected, wait for 1 min or more to allow the back up power
supply of the SAS control module to deplete its stored power after the cable is disconnected.
• Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is
necessary to note down the information stored in those memories before disconnecting the cable.
• When the ignition switch is turned to the ON position with the negative battery cable connected, the car
navigation unit starts program reading. To prevent a car navigation unit malfunction, do not start the engine
while “Program reading Do not turn the power off” is displayed on the screen (approx. 10 sec.).

Oil Leakage Inspection

• Use either of the following procedures to identify the type of oil that is leaking:

Using UV light (black light)

1. Remove any oil on the engine or transaxle/transmission.

Note
• Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or
ATF (or transaxle/transmission oil).

2. Pour the fluorescent dye into the engine oil or ATF (or transaxle/transmission oil).
3. Allow the engine to run for 30 min.
4. Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
5. If no dye leakage is found, allow the engine to run for another 30 min. or drive the vehicle then reinspect.
6. Find where the oil is leaking from, then make necessary repairs.

Note
• To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the
fluorescent dye instruction manual.

Not using UV light (black light)

1. Gather some of the leaking oil using an absorbent white tissue.
2. Take samples of engine oil and ATF (or transaxle/transmission oil), both from the dipstick, and place them next
to the leaked oil already on the tissue.
3. Compare the appearance and smell, and identify
the type of oil that is leaking.
4. Remove any oil on the engine or transaxle/
transmission. ATF OR
5. Allow the engine to run for 30 min. TRANSAXLE/
6. Check the area where the oil is leaking, then TRANSMISSION OIL ENGINE OIL
make necessary repairs.

LEAKED OIL
acxuuw00000008

Removal of Parts
• While correcting a problem, also try to determine
its cause. Begin work only after first learning
which parts and sub-components must be
removed and disassembled for replacement or
repair. After removing the part, plug all holes and
ports to prevent foreign material from entering.

acxuuw00000009

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GENERAL INFORMATION
Disassembly
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance, and
identified so that reassembly can be performed 00-00
easily and efficiently.

acxuuw00000010

Inspection During Removal, Disassembly

• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.

acxuuw00000011

Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.

acxuuw00000012

Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.

Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.

acxuuw00000013

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GENERAL INFORMATION
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, these parts should be replaced with
new ones:
— Oil seals
— Gaskets
— O-rings
— Lock washers
— Cotter pins
— Nylon nuts
acxuuw00000014

• Depending on location:
— Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.

acxuuw00000326

Adjustment
• Use suitable gauges and testers when making
adjustments.

acxuuw00000016

Rubber Parts and Tubing

• Prevent gasoline or oil from getting on rubber
parts or tubing.

acxuuw00000017

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GENERAL INFORMATION
Hose Clamps
• When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
00-00

acxuuw00000018

Torque Formulas
• When using a torque wrench-SST or equivalent
combination, the specified torque must be SST
recalculated due to the extra length that the SST

3
or equivalent adds to the torque wrench.

2
1
Recalculate the torque by using the following

0
formulas. Choose the formula that applies to you.

1
2
3
Torque Unit Formula
N·m N·m × [L/(L+A)]
kgf·m kgf·m × [L/(L+A)]
kgf·cm kgf·cm × [L/(L+A)] A L
ft·lbf ft·lbf × [L/(L+A)]
acxuuw00000019
in·lbf in·lbf × [L/(L+A)]

A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.

Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.

PROTECTIVE PLATES
acxuuw00000020

Dynamometer
• When inspecting and servicing the power train on the dynamometer or speedometer tester, pay attention to the
following:
— Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
— Make sure the vehicle is in a facility with an exhaust gas ventilation system.
— Since the rear bumper might deform from the heat, cool the rear with a fan. (Surface of the bumper must be
below 70°C {158°F} degrees.)
— Keep the area around the vehicle uncluttered so that heat does not build up.
— Watch the water temperature gauge and do not overheat the engine.
— Avoid added load to the engine and maintain normal driving conditions as much as possible.

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GENERAL INFORMATION
Note
• When only the front or rear wheels are rotated on a chassis dynamometer or equivalent, the DSC/RSC
HU/CM determines that there is a malfunction in the DSC/RSC and illuminates the following lights:
— ABS warning light
— Brake system warning light
— DSC indicator light
• If the above lights are illuminated, dismount the vehicle from the chassis dynamometer and turn the
ignition switch to the LOCK position. Then, turn the ignition switch back to the ON position, run the vehicle
at 10 km/h or more and verify that the warning lights go out. In this case, a DTC will be stored in the
memory. Clear the DTC from the memory by following the memory clearing procedure [DSC] in the on-
board diagnostic system. (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)

AWD inspection/service
Speedometer tester measurement

Caution
• Install the tension bar (chain wire) to the tie down hook and secure the vehicle to prevent it from
rolling and running off.
• Do not accelerate suddenly from a standstill or accelerate/decelerate rapidly.

Free roller type

1. Align the free rollers with the wheel base and tread, then set them on the floor properly.
2. Drive the vehicle slowly onto the tester roller and
free rollers.
3. Start the engine and accelerate gradually to
inspect the speedometer.
4. After inspection, decelerate gradually with gentle
braking.
Propeller shaft removal type
1. Remove the propeller shaft.
(See 03-15-2 PROPELLER SHAFT REMOVAL/
INSTALLATION.)

acxuuw00000327

2. Place the front wheels on the tester roller.

3. Accelerate gradually and inspect the
speedometer.
4. After inspection, decelerate gradually with gentle
braking.
5. Install the propeller shaft.
(See 03-15-2 PROPELLER SHAFT REMOVAL/
INSTALLATION.)

acxuuw00000329

Brake tester measurement

1. Place the wheels (front or rear) to be measured
on the tester roller.
2. Shift to the N position/neutral.
3. Activate the tester roller and measure braking
force. If there is a large amount of brake drag
force, the electronic control system coupling may
be affected. Jack up all four wheels to eliminate
the effect of the coupling and rotate each wheel
by hand to verify the rotation condition.

acxuuw00000328

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GENERAL INFORMATION
Wheel balancer (on the vehicle balancer)
1. Jack up all four wheels.
2. Support the wheels (front or rear) on the side to be measured (near the wheels) using a wheel balancer sensor
stand.
3. Support the wheels on the side not to be
measured (near the wheels) using safety stands. 00-00
4. Set up the wheel balancer and rotate the wheels
using engine drive to measure the wheel balance.

acxuuw00000330

SST
• Some global SST or equivalent are used as SSTs necessary for vehicle repair. Note that these SSTs are
marked with global SST numbers.
• Note that a global SST number is written together with a corresponding Mazda SST number as shown below.

Example (section **-60)

1: 49 UN303 009
2: 303-009

Crankshaft Damper Remover

1: Mazda SST number

2: Global SST number

acxuuw00000021

Example (Except section **-60)

303—009 —Global SST Number

(49 UN30 3009) —Mazda SST Number

acxuuw00000022

End Of Sie
INSTALLATION OF RADIO SYSTEM
id000000800300
• If a radio system is installed improperly or if a high-powered type system is used, the CIS and other systems
may be affected. When the vehicle is to be equipped with a radio, observe the following precautions:
— Install the antenna at the farthest point from control modules.
— Install the antenna feeder as far as possible from the control module wiring harnesses.
— Ensure that the antenna and feeder are properly adjusted.
— Do not install a high-powered radio system.
End Of Sie

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GENERAL INFORMATION
ELECTRICAL SYSTEM
id000000800400
Electrical Parts
Battery cable
• Before disconnecting connectors or removing
electrical parts, disconnect the negative battery NEGATIVE BATTERY CABLE
cable.

ac9uuw00002434

Wiring Harness
• To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.

acxuuw00000452

Caution
• Do not remove the wiring harness
protective tape. Otherwise, the wires NO GOOD
could rub against the body, which could
result in water penetration and electrical
shorting.

acxuuw00000453

Connectors
Disconnecting connectors
• When disconnecting a connector, grasp the
connectors, not the wires. GOOD NO GOOD

acxuuw00000454

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GENERAL INFORMATION
• Connectors can be disconnected by pressing or
pulling the lock lever as shown.

00-00

acxuuw00000455

Locking connector
• When locking connectors, listen for a click
indicating they are securely locked.

acxuuw00000456

Inspection

Caution
• To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into
terminal.

• When a tester is used to inspect for continuity or

measuring voltage, insert the tester probe from GOOD NO GOOD
the wiring harness side.

acxuuw00000457

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GENERAL INFORMATION
• Inspect the terminals of waterproof connectors
from the connector side since they cannot be GOOD NO GOOD
accessed from the wiring harness side.

acxuuw00000458

Terminals
Inspection
• Pull lightly on individual wires to verify that they
are secured in the terminal.

acxuuw00000459

Replacement
• Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it
locks securely.
• Insert a thin piece of metal from the terminal side
of the connector and with the terminal locking tab
pressed down, pull the terminal out from the TYPE A
connector.

TYPE B

acxuuw00000460

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GENERAL INFORMATION
Sensors, Switches, and Relays
• Handle sensors, switches, and relays carefully.
Do not drop them or strike them against other NO GOOD
objects.
00-00

acxuuw00000461

Wiring Harness
Wiring color codes
• Two-color wires are indicated by a two-color code symbol.
• The first letter indicates the base color of the wire
and the second is the color of the stripe.
CODE COLOR CODE COLOR B/R BR/Y
B Black O Orange
BR Brown P Pink BLACK BROWN
G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow RED YELLOW
LG Light Green – –

acxuuw00000462

Fuse
Replacement
• When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse malfunctions again, the
circuit probably has a short and the wiring should be inspected.
• Be sure the negative battery terminal is
disconnected before replacing a main fuse.

ac9uuw00002471

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GENERAL INFORMATION
• When replacing a pullout fuse, use the fuse puller.

PULLER

FUSE

acxuuw00000464

Viewing orientation for Connectors

• The viewing orientation for connectors is indicated with a symbol.
• The figures showing the viewing orientation are the same as those used in Wiring Diagrams.
• The viewing orientations are shown in the following three ways.

Part-side connector
The viewing orientation for part-side connectors is
from the terminal side. PART NAME*
* : Part names are shown only when there are
PCM
multiple connector drawings.

VIEWING
CONNECTOR ORIENTATION
SYMBOL

PART
VIEWING ORIENTATION
PART-SIDE CONNECTOR

acxuuw00000472

Vehicle harness-side connector

The viewing orientation for vehicle wiring harness- NAME OF CONNECTING
side connectors is from the wiring harness side. PART*
* : Part names are shown only when there are
multiple connector drawings. PCM

VIEWING
CONNECTOR ORIENTATION
SYMBOL

VEHICLE WIRING
HARNESS-SIDE
CONNECTOR VIEWING ORIENTATION

VEHICLE WIRING HARNESS

acxuuw00000473

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GENERAL INFORMATION
Other
When it is necessary to show the terminal side of the
vehicle wiring harness-side connectors, such as the
following connectors, the viewing orientation is from DLC-2
the terminal side.
• Main fuse block and the main fuse block relays 00-00
• Data link connector
• Check connector
• Relay box

CONNECTOR
VIEWING
ORIENTATION
SYMBOL

VEHICLE WIRING HARNESS VIEWING ORIENTATION

acxuuw00000474

Electrical Troubleshooting Tools

Jumper wire

Caution
• Do not connect a jumper wire from the power source line to a body ground. This may cause
burning or other damage to wiring harnesses or electronic components.

• A jumper wire is used to create a temporary

circuit. Connect the jumper wire between the
terminals of a circuit to bypass a switch.

acxuuw00000468

Voltmeter
• The DC voltmeter is used to measure circuit POWER SOURCE LINE
voltage. A voltmeter with a range of 15 V or more
is used by connecting the positive (+) probe (red
lead wire) to the point where voltage will be
measured and the negative (-) probe (black lead BLACK LEAD - V +
wire) to a body ground.

RED LEAD

acxuuw00000469

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GENERAL INFORMATION
Ohmmeter

Caution
• Do not connect the ohmmeter to any circuit where voltage is applied. This will damage the
ohmmeter.

• The ohmmeter is used to measure the resistance NO GOOD

between two points in a circuit and to inspect for
continuity and short circuits.
POWER SOURCE LINE

GROUND LINE
- Ω +

acxuuw00000470

Precautions Before Welding

A vehicle has various electrical parts. To protect the parts from excessive current generated when welding, be sure
to perform the following procedure.
1. Turn the ignition switch to the LOCK position.
2. Disconnect the battery cables.
BATTERY CABLE

acxuuw00000451

3. Securely connect the welding machine ground

near the welding area.
4. Cover the peripheral parts of the welding area to
protect them from weld spatter.
End Of Sie

GROUND

acxuuw00000471

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GENERAL INFORMATION
JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITIONS
id000000800500
Jacking Positions

Warning
• Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious 00-00
injury. Use only the correct front and rear jacking points and block the wheels.

• Use safety stands to support the vehicle after it has been lifted.

Front
• Near the center or the front crossmember.

ac9uuw00000509

Rear
2WD
• Near the center of the rear crossmember.

ac9uuw00000531

AWD
• At the center of the rear differential.

ac9uuw00000532

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GENERAL INFORMATION
Vehicle Lift Positions
Front and rear

Warning
• Lifting a vehicle that is not stabilized is dangerous. The vehicle can slip off the lift and cause
serious injury and/or vehicle damage. Make sure that the vehicle is on the lift horizontally by
adjusting the height of the support at the end of the arm of the lift.

Note
• The arrow at the rear of the vehicle indicates that it is the same as the illustration for the front of the
vehicle.

• Both sides of the vehicle, on side sills.

acxuuw00000068

Safety Stand Positions

Front and rear

Note
• The arrow at the rear of the vehicle indicates that it is the same as the illustration for the front of the
vehicle.

• Both sides of the vehicle, on side sills.

End Of Sie

acxuuw00000069

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GENERAL INFORMATION
TOWING
id000000800600
• Proper lifting and towing are necessary to prevent damage to the vehicle.Particularly when towing a AWD
vehicle, where all the wheels are connected to the drive train, proper transporting of the vehicle is absolutely
essential to avoid damaging the drive system. Government and local laws must be followed.
• A towed 2WD vehicle should have its drive wheels (front wheels) off the ground. If excessive damage or other 00-00
conditions prevent this, use wheel dollies.
• When towing a 2WD vehicle with the rear wheels on the ground, release the parking brake.
• A towed AWD vehicle must have all its wheels off
the ground.

WHEEL DOLLIES

acxuuw00000512

Caution
• Don't tow the vehicle pointed backward
with driving wheels on the ground. This
NO GOOD
may cause internal damage to the
transaxle.

ac9uuw00001725

Caution
• Don't tow with sling-type equipment. This
could damage the vehicle. Use wheel-lift
NO GOOD
or flatbed equipment.

ac9uuw00001726

Warning
• Always tow a AWD vehicle with all four
wheels off the ground. Towing a AWD
NO GOOD
vehicle with either the front or rear
wheels on the ground is dangerous as
the drive train could be damaged, or the
vehicle could trail away from the tow
truck and cause an accident. If the drive
train has been damaged, transport the
vehicle on a flat bed truck.

ac9uuw00001727

00-00–29
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GENERAL INFORMATION
Tiedown Hooks

Caution
• Don't use the tiedown hooks under the front and rear for towing. They are designed ONLY for tying
down the vehicle when it's being transported. Using them for towing will damage the bumper.

1. Remove the tiedown eyelet, lug wrench, and jack lever from the trunk.
2. Wrap the jack lever with a soft cloth to prevent
damage to the bumper and open the cap located
on the front and rear bumper.

ac9uuw00001277

Caution
• The cap cannot be completely removed.
Do not use excessive force as it may
damage the cap or scratch the painted
bumper surface.

ac9uuw00001278

3. Securely install the tiedown eyelet using the lug

wrench.

ac9uuw00001279

ac9uuw00001280

00-00–30
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GENERAL INFORMATION
4. Hook the tying rope to the tiedown eyelet.

00-00

ac9uuw00001281

Caution
• If the tiedown eyelet is not securely
tightened, it may loosen or disengage
from the bumper when tying down the
vehicle. Make sure that the tiedown
eyelet is securely tightened to the
bumper.

End Of Sie

ac9uuw00001282

TIEDOWN HOOK
id000000800700

Caution
• Do not use the tie down hook for towing the vehicle. Use it only for securing the vehicle.

Front

LF RF

FRONT

ac9uuw00000521

Rear

REAR
LR RR

ac9uuw00000522

End Of Sie

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GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATIONS
id000000800800
Vehicle Identification Number (VIN)

ac9uuw00001283

Engine Identification Number

FRONT

ac9uuw00001354

End Of Sie
SAE STANDARDS
id000000800900
• In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations
are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda
manuals up to now and their SAE equivalents.
SAE Standard SAE Standard
Remark Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal MAP Manifold Absolute Pressure
APP Accelerator Pedal Position MAF sensor Mass Air Flow Sensor
ACL Air Cleaner MFL Multiport Fuel Injection
A/C Air Conditioning OBD On-board Diagnostic System
BARO Barometric Pressure OL Open Loop
B+ Battery Positive Voltage OC Oxidation Catalytic Converter
CMP sensor Camshaft Position Sensor O2S Oxygen sensor
CAC Charge Air Cooler PNP Park/Neutral Position
CLS Closed Loop System PSP Power Steering Pressure
CTP Closed Throttle Position PCM Powertrain Control Module #3
CPP Clutch Pedal Position Pulsed
PAIR Pulsed Secondary Air Injection
CIS Continuous Fuel Injection System injection
CKP sensor Crankshaft Position Sensor Injection
DLC Data Link Connector AIR Secondary Air Injection with air
DTM Diagnostic Test Mode #1 pump
DTC Diagnostic Test Code(s) SAPV Secondary Air Pulse Valve
DI Distributor Ignition Sequential Multiport Fuel
SFI
DLI Distributorless Ignition Injection
EI Electronic Ignition #2 3GR Third Gear
ECT Engine Coolant Temperature TWC Three Way Catalytic Converter
EM Engine Modification TB Throttle Body
EVAP Evaporative Emission TP sensor Throttle Position Sensor

00-00–32
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GENERAL INFORMATION
SAE Standard SAE Standard
Remark Remark
Abbreviation Name Abbreviation Name
EGR Exhaust Gas Recirculation TCC Torque Converter Clutch
FC Fan Control Transmission (Transaxle) Control
TCM
FF Flexible Fuel Module 00-00
4GR Fourth Gear TR Transmission (Transaxle) Range
GEN Generator TC Turbocharger
GND Ground VSS Vehicle Speed Sensor
With VR Voltage Regulator
HO2S Heated Oxygen Sensor
heater VAF sensor Volume Air Flow Sensor
IAC Idle Air Control Warm Up Three Way Catalytic
WU-TWC #4
IAT Intake Air Temperature Converter
KS Knock Sensor WOP Wide Open Throttle
MIL Malfunction Indicator Lamp

#1: Diagnostic trouble codes depend on the diagnostic test mode.

#2: Controlled by the PCM
#3: Device that controls engine and powertrain
#4: Directly connected to exhaust manifold
End Of Sie
ABBREVIATIONS
id000000801000

ABS Antilock Brake System LR Left Rear

ACC Accessories M Motor
ALR Automatic Locking Retractor MAX Maximum
ATF Automatic Transaxle Fluid OCV Oil Control Valve
ATX Automatic Transaxle PDS Portable Diagnostic Software
AWD All-Wheel Drive PID Parameter Identification
BCM Body Control Module POWER MOS Power Metal Oxide Semiconductor Field
FET Effect Transistor
CAN Controller Area Network
P/W Power Window
CCM Comprehensive Component Monitor
RAM Random Access Memory
CHT Cylinder Head Temperature
RES Rear Entertainment System
CM Control Module
RF Right Front
CPU Central Processing Unit
RH Right Hand
DC Drive Cycle
ROM Read Only Memory
DEF Defroster
RR Right Rear
DLC-2 Data Link Connector-2
RSC Roll Stability Control
DRL Daytime Running Lamp
SAS Sophisticated Air Bag Sensor
DSC Dynamic Stability Control
SST Special Service Tool
EBD Electronic Brakeforce Distribution
SW Switch
ELR Emergency Locking Retractor
TCS Traction Control System
GPS Global Positioning System
TDC Top Dead Center
HF/TEL Hands-Free Telephone
TFT Transaxle Fluid Temperature
HI High
TNS Tail Number Side Lights
HU Hydraulic Unit
TPMS Tire Pressure Monitoring System
IDS Integrated Diagnostic Software
VENT Ventilation
IG Ignition
1GR First Gear
INT Intermittent
2GR Second Gear
KOEO Key On Engine Off
2WD 2-wheel Drive
KOER Key On Engine Running
3GR Third Gear
LCD Liquid Crystal Display
4GR Fourth Gear
LED Light Emitting Diode
5GR Fifth Gear
LF Left Front
6GR Sixth Gear
LH Left Hand
LO Low

00-00–33
1890-1U-06H(00-00).fm 34 ページ ２００６年１２月１９日　火曜日　午前１０時１９分

GENERAL INFORMATION
End Of Sie

PRE-DELIVERY INSPECTION
id000000801100
Pre-Delivery Inspection Table
Exterior
INSPECT and ADJUST, if necessary, the following items to specification:
❏ Glass, exterior bright metal and paint for damage
❏ Wheel lug nuts
❏ All weatherstrips for damage or detachment
❏ Tire pressures
❏ Operation of hood release and lock
❏ Operation of fuel-filler lid opener
❏ Door operation and alignment including side door and back door
❏ Headlight aiming
INSTALL the following parts:
❏ Flap (front)
❏ Wheel caps or rings (if equipped)

Under hood—engine off

INSPECT and ADJUST, if necessary, the following items to specification:
❏ Fuel, engine coolant, and hydraulic lines, fittings, connections, and components for leaks
❏ Engine oil level
❏ Power steering fluid level
❏ Brake fluid level
❏ Washer tank fluid level
❏ Radiator coolant level and specific gravity
❏ Tightness of water hose clamps
❏ Tightness of battery terminals, electrolyte level and specific gravity

Interior
INSTALL the following items:
❏ Fuse for accessories
INSPECT the operations of the following items:
❏ Seat controls (slide and recline) and headrests
❏ Folding rear seat
❏ Door locks, including childproof door locks
❏ Seat belts and warning system
❏ Ignition switch and steering lock
❏ Transaxle range switch
❏ Warning buzzers
❏ Ignition key reminder alarm
❏ Air bag system using warning light
❏ Cruise control system (if equipped)
❏ Power door lock
❏ Shift-lock system (if equipped)
❏ Starter interlock
❏ All lights including warning, and indicator lights
❏ Horn, wipers, and washers
❏ Wiper blades performance
Clean wiper blades and windshield, if necessary
❏ Antenna
❏ Audio system
❏ Cigarette lighter and clock
❏ Power windows (if equipped)
❏ Heater, defroster, and air conditioner at various mode selections (if equipped)
INSPECT the following items:
❏ Presence of spare fuse
❏ Upholstery and interior finish
INSPECT and ADJUST, if necessary, the following items:
❏ Operation and fit of windows
❏ Parking brake

00-00–34
1890-1U-06H(00-00).fm 35 ページ ２００６年１２月１９日　火曜日　午前１０時１９分

GENERAL INFORMATION
Under hood—engine running at operating temperature
INSPECT the following items:
❏ Automatic transaxle fluid level
❏ Operation of idle-up system for electrical load, air conditioner or power steering (if equipped)
❏ Ignition timing
❏ Idle speed 00-00
❏ Operation of throttle position sensor

On hoist
INSPECT the following items:
❏ Underside fuel, coolant and hydraulic lines, fittings, connections, and components for leaks
❏ Tires for cuts or bruises
❏ Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage
❏ Differential oil level

Road test
INSPECT the following items:
❏ Brake operation
❏ Steering control
❏ Operation of gauges
❏ Squeaks, rattles, and unusual noises
❏ Engine general performance
❏ Emergency locking retractors and automatic locking retractors
❏ Cruise control system (if equipped)
❏ Operation of meters and gauges, squeaks, rattles, and abnormal noises

After road test

INSPECT for necessary owner information materials, tools, and spare tire in vehicle
The following items must be completed just before delivery to your customer.
❏ Load test battery and charge if necessary (Load test result: Volts)
❏ Adjust tire pressure to specification (Specified tire pressure is indicated on the door label.)
❏ Clean outside of vehicle
❏ Install fuses for accessories
❏ Remove seat and cabin carpet protective covers
❏ Vacuum inside of vehicle
End Of Sie

00-00–35
1890-1U-06H(00-00).fm 36 ページ ２００６年１２月１９日　火曜日　午前１０時１９分

GENERAL INFORMATION
SCHEDULED MAINTENANCE
id000000801200
Scheduled Maintenance Table for U.S.A., CANADA and Puerto Rico
Schedule 1: (Normal Driving Conditions) for U.S.A.
• The vehicle is mainly operated where none of the “unique driving conditions” apply.
Number of months or kilometers (miles), whichever comes first
Months 6 12 18 24 30 36 42 48
Maintenance Interval
×1000 km 12 24 36 48 60 72 84 96
×1000 miles 7.5 15 22.5 30 37.5 45 52.5 60
ENGINE
Inspect every 168,000 km (105,000 miles)
Drive belts
Replace every 240,000 km (150,000 miles)
Engine oil R R R R R R R R
Engine oil filter R R R R R R R R
COOLING SYSTEM
Replace at first 192,000 km (120,000 miles) or 10 years;
FL22 type *1 after that, every 96,000 km (60,000 miles) or 5 years
Engine coolant
Replace at first 96,000 km (60,000 miles) or 4 years;
Others
after that, every 2 years
FUEL SYSTEM
Air cleaner element C R C
*2 I I
Fuel lines and hoses
Hoses and tubes for emission *2 I
IGNITION SYSTEM
Spark plugs Replace every 160,000 km (100,000 miles)
CHASSIS and BODY
Brake lines, hoses and connections I I
Disc brakes I I I I
Tire (Rotation) Rotate every 12,000 km (7,500 miles)
Steering operation and linkages I I
Front and rear suspension, ball joints and wheel
I I
bearing axial play
Rear differential oil (AWD) *3 *4

Driveshaft dust boots I I

Bolts and nuts on chassis and body T T
Exhaust system and heat shields Inspect every 72,000 km (45,000 miles) or 5 years
All locks and hinges L L L L L L L L
AIR CONDITIONER SYSTEM
Cabin air filter Replace every 40,000 km (25,000 miles) or 2 years

Chart symbols:
I: Inspect and repair, clean, adjust, or replace if necessary.
R: Replace
C: Clean
T: Tighten
L: Lubricate
Remarks
• After the prescribed period, continue to follow the described maintenance at the recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1: Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or the surrounding
area. Use FL22 when replacing the coolant.
*2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not
void your emissions warranties. However, Mazda recommends that all maintenance services be performed
at the recommended time or mileage/kilometer period to ensure long-term reliability.
*3: If the vehicle is operated primarily under any of the following conditions, replace the rear differential oil at
every 45,000 km (28,100 miles).
a. Towing a trailer or using a car-top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km (10 miles)
*4: If this component has been submerged in water, the oil should be replaced.

00-00–36
1890-1U-06H(00-00).fm 37 ページ ２００６年１２月１９日　火曜日　午前１０時１９分

GENERAL INFORMATION
Schedule 2: CANADA, Puerto Rico and (Unique Driving Conditions) for U.S.A.
• Repeated short-distance driving
• Driving in dusty conditions
• Driving with extended use of brakes
• Driving in areas where salt or other corrosive materials are used
• Driving on rough or muddy roads 00-00
• Extended periods of idling or low-speed operation
• Driving for long periods in cold temperatures or extremely humid climates
Number of months or kilometers (miles), whichever comes first
Months 4 8 12 16 20 24 28 32 36 40 44 48
Maintenance Interval
×1000 km 8 16 24 32 40 48 56 64 72 80 88 96
×1000 miles 5 10 15 20 25 30 35 40 45 50 55 60
ENGINE
Inspect every 160,000 km (100,000 miles)
Drive belts
Replace every 240,000 km (150,000 miles)
Puerto Rico Replace every 5,000 km (3,000 miles) or 3 months
Engine oil
Others R R R R R R R R R R R R
Engine oil filter R R R R R R R R R R R R
COOLING SYSTEM
Replace at first 192,000 km (120,000 miles) or 10 years;
FL22 type *1 after that, every 96,000 km (60,000 miles) or 5 years
Engine coolant
Others Replace at first 96,000 km (60,000 miles) or 4 years; after that, every 2 years
Engine coolant level I I I I I I I I I I I I
FUEL SYSTEM
Puerto Rico C R C R
Air cleaner element
Others C R C
Fuel lines and hoses *2 I I
*2 I
Hoses and tubes for emission
IGNITION SYSTEM
USA Replace every 96,000 km (60,000 miles)
Spark plugs
Others *3 Replace every 160,000 km (100,000 miles)
ELECTRICAL SYSTEM
Function of all lights I I I I I I I I I I I I
CHASSIS and BODY
Brake lines, hoses and connections I I
Brake fluid level I I I I I I I I I I I I
Disc brakes I I I I
Tire (Rotation) Rotate every 8,000 km (5,000 miles)
Tire inflation pressure and tire wear I I I I I I I I I I I I
Steering operation and linkages I I
Power steering fluid level I I I I I I I I I I I I
Front and rear suspension, ball joints and
I I
wheel bearing axial play
Rear differential oil (AWD) *4 *5

Driveshaft dust boots I I

Bolts and nuts on chassis and body T T
Exhaust system and heat shields Inspect every 72,000 km (45,000 miles) or 5 years
All locks and hinges L L L L L L L L L L L L
Washer fluid level I I I I I I I I I I I I
AIR CONDITIONER SYSTEM
Cabin air filter Replace every 40,000 km (25,000 miles) or 2 years

00-00–37
1890-1U-06H(00-00).fm 38 ページ ２００６年１２月１９日　火曜日　午前１０時１９分

GENERAL INFORMATION
Chart symbols:
I: Inspect and repair, clean, adjust, or replace if necessary.
R: Replace
C: Clean
T: Tighten
L: Lubricate
Remarks
• After the prescribed period, continue to follow the described maintenance at the recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1: Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or the surrounding
area. Use FL22 when replacing the coolant.
*2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not
void your emissions warranties. However, Mazda recommends that all maintenance services be performed
at the recommended time or mileage/kilometer period to ensure long-term reliability.
*3: If the vehicle is operated primarily under any of the following conditions, replace the spark plugs at every
96,000 km (60,000 miles) or shorter.
a. Repeated short-distance driving
b. Extended periods of idling or low-speed operation
c. Driving for long periods in cold temperatures or extremely humid climates
*4: If the vehicle is operated primarily under any of the following conditions, replace the rear differential oil at
every 45,000 km (28,100 miles).
a. Towing a trailer or using a car-top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km (10 miles)
*5: If this component has been submerged in water, the oil should be replaced.

00-00–38
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
GENERAL INFORMATION
Scheduled Maintenance Table for Mexico
Schedule 1: (Normal Driving Conditions) for Mexico
• The vehicle is mainly operated where none of the “unique driving conditions” apply.
Number of months or kilometers, whichever comes first
Maintenance Interval Months 6 12 18 24 30 36 42 48 54 60 66 72
00-00
×1000 km 10 20 30 40 50 60 70 80 90 100 110 120
ENGINE
Drive belts Inspect every 40,000 km or 2 years Replace every 240,000 km
Engine oil R R R R R R R R R R R R
Engine oil filter R R R R R R R R R R R R
COOLING SYSTEM
Cooling system I I I
FL22 type *1 Replace at first 190,000 km or 10 years; after that, every 60,000 km or 3 years
Engine coolant
Others R R R
FUEL SYSTEM
Air cleaner element R R R R R R
Fuel lines and hoses I*2 I*2 I
Hoses and tubes for emission I*2 I*2 I
Fuel filter R R R
IGNITION SYSTEM
Spark plugs Replace every 60,000 km
CHASSIS and BODY
Brake lines, hoses and connections I I I I I I
Brake fluid level I I I I I I I I I
Brake fluid R R R
Disc brakes I I I I I I I I I I I I
Tire (Rotation) Rotate every 10,000 km
Tire inflation pressure and tire wear I I I I I I I I I I I I
Steering operation and linkages I I I I I I I I I I I I
Power steering fluid level I I I I I I I I I I I I
Front and rear suspension, ball joints and
I I I I I I
wheel bearing axial play
Rear differential oil (AWD) *3 *4

Driveshaft dust boots I I I I I I

Bolts and nuts on chassis and body T T T T T T
Exhaust system and heat shields I I I I I I
All locks and hinges L L L L L L L L L L L L
Washer fluid level I I I I I I I I I I I I
AIR CONDITIONER SYSTEM
Cabin air filter R R R

Chart symbols:
I: Inspect and repair, clean, adjust, or replace if necessary.
R: Replace
C: Clean
T: Tighten
L: Lubricate
Remarks
• After the prescribed period, continue to follow the described maintenance at the recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1: Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or the surrounding
area. Use FL22 when replacing the coolant.
*2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not
void your emissions warranties. However, Mazda recommends that all maintenance services be performed
at the recommended time or kilometer period to ensure long-term reliability.
*3: If the vehicle is operated primarily under any of the following conditions, replace the rear differential oil at
every 40,000 km.
a. Towing a trailer or using a car-top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km
*4: If this component has been submerged in water, the oil should be replaced.
Revised 1/2007 (Ref. No. R009/07) 00-00–39
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
GENERAL INFORMATION
Schedule 2: (Unique Driving Conditions) for Mexico
• Repeated short-distance driving
• Driving in dusty conditions
• Driving with extended use of brakes
• Driving in areas where salt or other corrosive materials are used
• Driving on rough or muddy roads
• Extended periods of idling or low-speed operation
• Driving for long periods in cold temperatures or extremely humid climates
• Driving in extremely hot conditions
• Driving in mountainous conditions continually
Number of months or kilometers, whichever comes first
Maintenance Interval Months 3 6 9 12 15 18 21 24 27 30 33 36
×1000 km 5 10 15 20 25 30 35 40 45 50 55 60
ENGINE
Drive belts Inspect every 40,000 km or 2 years Replace every 240,000 km
Engine oil R R R R R R R R R R R R
Engine oil filter R R R R R R R R R R R R
COOLING SYSTEM
Cooling system I
Replace at first 190,000 km or 10 years;
FL22 type *1 after that, every 60,000 km or 3 years
Engine coolant
Others R
Engine coolant level I I I I I I I I I I I I
FUEL SYSTEM
Air cleaner element C R C R C R
Fuel lines and hoses *2
I
Hoses and tubes for emission I*2
Fuel filter R
IGNITION SYSTEM
Spark plugs Replace every 60,000 km
ELECTRICAL SYSTEM
Function of all lights I I I I I I I I I I I I
CHASSIS and BODY
Brake lines, hoses and connections I I I
Brake fluid level I I I I I
Brake fluid R
Disc brakes I I I I I I
Tire (Rotation) Rotate every 10,000 km
Tire inflation pressure and tire wear I I I I I I
Steering operation and linkages I I I I I I
Power steering fluid level I I I I I I
Front and rear suspension, ball joints and wheel
I I I
bearing axial play
Rear differential oil (AWD) *3 *4

Driveshaft dust boots I I I

Bolts and nuts on chassis and body T T T
Exhaust system and heat shields I I I
All locks and hinges L L L L L L
Washer fluid level I I I I I I
AIR CONDITIONER SYSTEM
Cabin air filter R R R

00-00–40 Revised 1/2007 (Ref. No. R009/07)

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
GENERAL INFORMATION

00-00

Cont.
Number of months or kilometers, whichever comes first
Maintenance Interval Months 39 42 45 48 51 54 57 60 63 66 69 72
×1000 km 65 70 75 80 85 90 95 100 105 110 115 120
ENGINE
Drive belts Inspect every 40,000 km or 2 years Replace every 240,000 km
Engine oil R R R R R R R R R R R R
Engine oil filter R R R R R R R R R R R R
COOLING SYSTEM
Cooling system I I
Replace at first 190,000 km or 10 years;
FL22 type *1 after that, every 60,000 km or 3 years
Engine coolant
Others R R
Engine coolant level I I I I I I I I I I I I
FUEL SYSTEM
Air cleaner element C R C R C R
Fuel lines and hoses I*2 I
Hoses and tubes for emission I*2 I
Fuel filter R R
IGNITION SYSTEM
Spark plugs Replace every 60,000 km
ELECTRICAL SYSTEM
Function of all lights I I I I I I I I I I I I
CHASSIS and BODY
Brake lines, hoses and connections I I I
Brake fluid level I I I I
Brake fluid R R
Disc brakes I I I I I I
Tire (Rotation) Rotate every 10,000 km
Tire inflation pressure and tire wear I I I I I I
Steering operation and linkages I I I I I I
Power steering fluid level I I I I I I
Front and rear suspension, ball joints and wheel
I I I
bearing axial play
Rear differential oil (AWD) *3 *4

Driveshaft dust boots I I I

Bolts and nuts on chassis and body T T T
Exhaust system and heat shields I I I
All locks and hinges L L L L L L
Washer fluid level I I I I I I
AIR CONDITIONER SYSTEM
Cabin air filter R R R

Chart symbols:
I: Inspect and repair, clean, adjust, or replace if necessary.
R: Replace
C: Clean
T: Tighten
L: Lubricate
Revised 1/2007 (Ref. No. R009/07) 00-00–41
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
GENERAL INFORMATION
Remarks
• After the prescribed period, continue to follow the described maintenance at the recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1: Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or the surrounding
area. Use FL22 when replacing the coolant.
*2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not
void your emissions warranties. However, Mazda recommends that all maintenance services be performed
at the recommended time or kilometer period to ensure long-term reliability.
*3: If the vehicle is operated primarily under any of the following conditions, replace the rear differential oil at
every 40,000 km.
a. Towing a trailer or using a car-top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km
*4: If this component has been submerged in water, the oil should be replaced.
End Of Sie
HANDLING SPARE TIRE
id000000801700
Remove The Spare Tire
1. Open the trunk board.
2. Remove the cover.

Caution
• Always use the tools equipped to the
vehicle when performing spare tire
removal/installation, otherwise the spare
tire carrier may be damaged.

COVER

ac9uuw00002621

3. Attach the socket to the spare tire carrier bolt, the

jack lever to the socket, and the lug wrench to the
opposite end of the jack lever. LUG WRENCH

JACK LEVER

SOCKET

SPARE TIRE
CRRIER BOLT

ac9uuw00002622

4. Slowly turn the lug wrench counterclockwise until

the spare tire reaches the ground and the cable
becomes loose.

Caution
• Do not loosen the cable too much as this
may cause damage to the spare tire
carrier.

SPARE TIRE

ac9uuw00002623

00-00–42 Added 1/2007 (Ref. No. R009/07)

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
GENERAL INFORMATION
5. Rotate the lever on top of the retaining plate and
pull the retaining plate out from the center hole of LEVER
the tire.

Note
• If the temporary spare tire is not reinstalled 00-00
in the spare tire carrier, tighten the spare tire
carrier bolt completely to wind up the spare
tire carrier cable, and make sure to tighten it
until a click sound is heard.

ac9uuw00002624

Install The Spare Tire

Warning
• Securely tighten the spare tire carrier bolt until a click sound is heard. If the spare tire carrier bolt
is not tightened securely, the spare tire carrier cable could sever and cause the spare tire to fall
off, resulting in an accident.

1. Place the tire with the outer side facing upward,

rotate the lever on top of the retaining plate and
LEVER
slide the retaining plate through the center hole of
the tire. Rotate the lever into place.

Caution
• Always use the tools equipped to the
vehicle when performing spare tire
removal/installation, otherwise the spare
tire carrier may be damaged.

2. Raise the spare tire slowly in reverse order of

removal, and make sure to tighten it until a click
sound is heard.
End Of Sie LEVER

SPARE TIRE
RETAINING PLATE

ac9uuw00002625

Added 1/2007 (Ref. No. R009/07) 00-00–43

1890-1U-06H(01-02).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ENGINE 01SECTION

01-02
Toc of SCT
ON-BOARD DIAGNOSTIC EMISSION SYSTEM
[MZI-3.5] . . . . . . . . . . . . . . . . . 01-02 [MZI-3.5]. . . . . . . . . . . . . . . . . 01-16
SYMPTOM CHARGING SYSTEM
TROUBLESHOOTING [MZI-3.5]. . . . . . . . . . . . . . . . . 01-17
[MZI-3.5] . . . . . . . . . . . . . . . . . 01-03 IGNITION SYSTEM
MECHANICAL[MZI-3.5] . . . . . . 01-10 [MZI-3.5]. . . . . . . . . . . . . . . . . 01-18
LUBRICATION[MZI-3.5] . . . . . . 01-11 STARTING SYSTEM
COOLING SYSTEM [MZI-3.5]. . . . . . . . . . . . . . . . . 01-19
[MZI-3.5] . . . . . . . . . . . . . . . . . 01-12 CRUISE CONTROL SYSTEM
INTAKE-AIR SYSTEM [MZI-3.5]. . . . . . . . . . . . . . . . . 01-20
[MZI-3.5] . . . . . . . . . . . . . . . . . 01-13 CONTROL SYSTEM
FUEL SYSTEM[MZI-3.5] . . . . . . 01-14 [MZI-3.5]. . . . . . . . . . . . . . . . . 01-40
EXHAUST SYSTEM TECHNICAL DATA
[MZI-3.5] . . . . . . . . . . . . . . . . . 01-15 [MZI-3.5]. . . . . . . . . . . . . . . . . 01-50
SERVICE TOOLS
[MZI-3.5]. . . . . . . . . . . . . . . . . 01-60
Toc of SCT
01-02 ON-BOARD DIAGNOSTIC [MZI-3.5]
FOREWORD [MZI-3.5] . . . . . . . . . . . . . . . 01-02–3 DTC P0021 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–25
ON-BOARD DIAGNOSTIC TEST DTC P0022 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–26
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-02–3 DTC P0040, P0041 [MZI-3.5] . . . . . . . . . 01-02–27
DTC Reading Procedure. . . . . . . . . . . . 01-02–3 DTC P0053, P0054, P0059, P0060
Pending Trouble Code Access [MZI-3.5]. . . . . . . . . . . . . . . . . . . . . . . . . 01-02–27
Procedure . . . . . . . . . . . . . . . . . . . . . . 01-02–4 DTC P0068 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–30
Freeze Frame PID Data Access DTC P0102 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–32
Procedure . . . . . . . . . . . . . . . . . . . . . . 01-02–4 DTC P0103 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–34
On-Board System Readiness Tests DTC P0104 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–36
Access Procedure . . . . . . . . . . . . . . . . 01-02–4 DTC P0111 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–38
PID/DATA Monitor and Record DTC P0112 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–39
Procedure . . . . . . . . . . . . . . . . . . . . . . 01-02–5 DTC P0113 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–41
Diagnostic Monitoring Test Results DTC P0114 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–43
Access Procedure . . . . . . . . . . . . . . . . 01-02–7 DTC P0116 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–44
Simulation Function Procedure . . . . . . . 01-02–7 DTC P0119 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–45
AFTER REPAIR PROCEDURE DTC P0122 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–46
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-02–8 DTC P0123 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–48
KOEO/KOER SELF TEST DTC P0128 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–50
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-02–8 DTC P0132, P0138, P0152, P0158
OBD-II DRIVE MODE [MZI-3.5] . . . . . . . . 01-02–9 [MZI-3.5]. . . . . . . . . . . . . . . . . . . . . . . . . 01-02–51
DIAGNOSTIC MONITORING TEST DTC P0133, P0139, P0153, P0159
RESULTS [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–11 [MZI-3.5]. . . . . . . . . . . . . . . . . . . . . . . . . 01-02–53
DTC TABLE [MZI-3.5] . . . . . . . . . . . . . . . 01-02–12 DTC P0135, P0141, P0155, P0161
DTC B1342 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–17 [MZI-3.5]. . . . . . . . . . . . . . . . . . . . . . . . . 01-02–58
DTC P0010 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–18 DTC P0148 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–62
DTC P0011 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–20 DTC P0171, P0174 [MZI-3.5] . . . . . . . . . 01-02–65
DTC P0012 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–21 DTC P0172, P0175 [MZI-3.5] . . . . . . . . . 01-02–69
DTC P0016, P0018 [MZI-3.5] . . . . . . . . . . 01-02–22 DTC P0201 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–71
DTC P0020 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–23 DTC P0202 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–73

01-02–1
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0203 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–75 DTC P061B [MZI-3.5] . . . . . . . . . . . . . . . 01-02–167
DTC P0204 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–77 DTC P061C [MZI-3.5] . . . . . . . . . . . . . . . 01-02–168
DTC P0205 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–79 DTC P061F [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–169
DTC P0206 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–81 DTC P0620 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–170
DTC P0222 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–83 DTC P0625 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–172
DTC P0223 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–85 DTC P0626 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–174
DTC P0230 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–87 DTC P0642 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–176
DTC P0231 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–89 DTC P0643 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–178
DTC P0232 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–91 DTC P0645 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–180
DTC P0297 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–93 DTC P0685 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–183
DTC P0300 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–94 DTC P0689 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–185
DTC P0301, P0302, P0303, P0304, DTC P0690 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–187
P0305, P0306, P0316 [MZI-3.5] . . . . . . . 01-02–97 DTC P1000 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–189
DTC P0315 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–100 DTC P1001 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–190
DTC P0320 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–101 DTC P1101 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–191
DTC P0325 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–104 DTC P1127 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–193
DTC P0330 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–106 DTC P115E [MZI-3.5] . . . . . . . . . . . . . . . 01-02–194
DTC P0340 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–108 DTC P1260 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–195
DTC P0344 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–111 DTC P1285, P1299 [MZI-3.5] . . . . . . . . . 01-02–196
DTC P0345 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–114 DTC P1288 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–198
DTC P0349 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–117 DTC P1289 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–199
DTC P0351, 0352, 0353, 0354, 0355, DTC P1290 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–201
0356 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . 01-02–119 DTC P1336 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–202
DTC P0420, P0430 [MZI-3.5] . . . . . . . . . . 01-02–122 DTC P1397 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–204
DTC P0442, P0456 [MZI-3.5] . . . . . . . . . . 01-02–123 DTC P1450 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–204
DTC P0443 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–126 DTC P145E [MZI-3.5] . . . . . . . . . . . . . . . 01-02–206
DTC P0446 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–128 DTC P1464 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–209
DTC P0451 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–130 DTC P1500 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–210
DTC P0452 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–131 DTC P1501 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–211
DTC P0453 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–133 DTC P1633 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–212
DTC P0454 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–135 DTC P1635 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–213
DTC P0455 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–136 DTC P1639 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–214
DTC P0457 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–138 DTC P1650 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–214
DTC P0460 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–139 DTC P1674 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–216
DTC P0461 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–140 DTC P1703 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–217
DTC P0462 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–141 DTC P2100 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–219
DTC P0463 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–141 DTC P2101 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–221
DTC P0480 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–142 DTC P2104, P2105, P2110
DTC P0505 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–145 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-02–222
DTC P0506 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–147 DTC P2107 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–223
DTC P0507 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–148 DTC P2111 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–225
DTC P050E [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–148 DTC P2112 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–228
DTC P053A [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–150 DTC P2121, P2126, P2131
DTC P0579 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–154 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-02–230
DTC P0581 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–156 DTC P2122 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–234
DTC P0600 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–158 DTC P2123 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–236
DTC P0602 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–159 DTC P2127 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–238
DTC P0603 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–160 DTC P2128 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–240
DTC P0604 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–162 DTC P2132 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–242
DTC P0605 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–162 DTC P2133 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–244
DTC P0606 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–163 DTC P2135 [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–246
DTC P0607 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–164 DTC P2195, P2197 [MZI-3.5] . . . . . . . . . 01-02–248
DTC P060A, P060C, P061D DTC P2196, P2198 [MZI-3.5] . . . . . . . . . 01-02–250
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-02–164 DTC P2270, P2272 [MZI-3.5] . . . . . . . . . 01-02–252
DTC P060B [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–165 DTC P2271, P2273 [MZI-3.5] . . . . . . . . . 01-02–253
DTC P0610 [MZI-3.5] . . . . . . . . . . . . . . . . 01-02–166 DTC P260F [MZI-3.5]. . . . . . . . . . . . . . . . 01-02–254

End of Toc
WM: ON-BOARD DIAGNOSTIC (ENGINE CONTROL SYSTEM)

01-02–2
1890-1U-06H(01-02).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

FOREWORD [MZI-3.5]
id0102d1800300
• When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL) indication and
diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart.
— If the DTC exists, diagnose the applicable DTC inspection. (See 01-02-12 DTC TABLE [MZI-3.5].)
— If the DTC does not exist and the MIL does not illuminate, diagnose the applicable symptom
troubleshooting.
01-02
CUSTOMER ARRIVES

WARNING LIGHT* NO WARNING LIGHT*

ON/FLASHING WITH SYMPTOM

CHECK FOR •CHECK DTC

PRIORITIZED DTC •ENGINE ON TEST, IDLING TEST
DTC
WITHOUT DTC

DIAGNOSE BY DTC DIAGNOSE BY SYMPTOM

(ON-BOARD DIAGNOSTIC) (SYMPTOM TROUBLESHOOTING)
•DTC TABLE 1. DIAGNOSTIC INDEX
•DTC 2. QUICK DIAGNOSIS CHART
TROUBLESHOOTING 3. SYMPTOM TROUBLESHOOTING
FLOW

atraaw00000607

*: MIL, Generator Warning Light, Security Light

End Of Sie
ON-BOARD DIAGNOSTIC TEST [MZI-3.5]
id0102d1801000
DTC Reading Procedure
1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “PCM”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “PCM”.
3. Select “Self Test”.
ac9uuw00001090
3. Then, select the “Retrieve CMDTCs” and perform
procedures according to directions on the M-MDS
screen.
4. Verify the DTC according to the directions on the M-MDS screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
5. After completion of repairs, clear all DTCs stored in the PCM, while referring to “AFTER REPAIR
PROCEDURE“.

01-02–3
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ON-BOARD DIAGNOSTIC [MZI-3.5]

Pending Trouble Code Access Procedure
1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “PCM”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “PCM”.
3. Select “Self Test”.
ac9uuw00001090
3. Then, select the “Retrieve CMDTCs” and perform
procedures according to directions on the M-MDS
screen.
4. Retrieve the pending trouble codes according to the directions on the M-MDS screen.

Freeze Frame PID Data Access Procedure

1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “PCM”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “PCM”.
3. Select “Self Test”.
ac9uuw00001090
3. Then, select the “Retrieve CMDTCs” and perform
procedures according to directions on the M-MDS
screen.
4. Retrieve the freeze frame PID data according to the directions on the M-MDS screen.

On-Board System Readiness Tests Access Procedure

1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Powertrain”.
3. Select “OBD Test Modes”.
4. Select “Mode 1 Powertrain Data”.
5. Select “PCM”. DLC-2
• When using the PDS (Pocket PC)
1. Select “OBDII Modes”.
2. Select “Mode 1 Powertrain Data”.
ac9uuw00001090
3. Select “PCM”.
3. Then, select the “***SUP” and “**EVAL” PIDs in
the PID selection screen.
4. Monitor those PIDs and check it system monitor is completed.

Note
• If the on-board system readiness tests are not completed the PCM stores DTC P1000.

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ON-BOARD DIAGNOSTIC [MZI-3.5]

PID/DATA Monitor and Record Procedure

Note
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM.
Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value
for the output device. If a monitored value of an output device is out of specification, inspect the monitored
value of the input device related to the output control.
01-02
1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “PCM”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “PCM”.
3. Select “DataLogger”.
ac9uuw00001090
3. Select the PID from the PID table.
4. Verify the test results according to detections on
the screen.

PID/Data Monitor Table

PID Name Description Unit
AAT Indicate the ambient air temperature °C
AC_REQ A/C request signal Off/On
ACCS A/C relay Off/On
ALTF Generator field coil control duty value %
APP Accelerator pedal position %
%
APP1 APP sensor No.1
V
%
APP2 APP sensor No.2
V
%
APP3 APP sensor No.3
V
ARPMDES Target engine speed RPM
AXLE Axle ratio —
BARO Barometric pressure Pa
BOO Brake switch Off/On
BPA Brake pressure applied switch Off/On
CATT11_DSD Estimated catalytic converter temperature (RH) °C
CATT21_DSD Estimated catalytic converter temperature (LH) °C
CHRGLP Generator warning light Off/On
°C
CHT CHT sensor
V
COLP Refrigerant pressure switch (middle) Off/On
DTCCNT Number of DTCs detected —
ECT Engine coolant temperature °C
EQ_RAT11_DSD Desired equivalence ratio (lambda) -
ETC_ACT Electronic throttle control actual °
%
ETC_DSD Electronic throttle control desired
°
EVAPCP Purge solenoid valve duty value %
EVAPCV CV solenoid valve Off/On
EVMV Evaporative Emission Vapor Management valve mA
FAN_DUTY Cooling fan control %

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ON-BOARD DIAGNOSTIC [MZI-3.5]

PID Name Description Unit
FLI Fuel level %
FP Fuel pump relay Off/On
FPM Fuel pump monitor Off/On
FTP Fuel tank pressure sensor V
FTP_H2O Fuel tank pressure (inches of water column) —
OL/CL/OL-Drive/OL-
FUELSYS1 Fuel system loop status (RH)
Fault/CL-Fault
GENVDSD Generator voltage desired V
HTR11 Front HO2S heater (RH) Off/On
HTR12 Rear HO2S heater (RH) Off/On
HTR21 Front HO2S heater (LH) Off/On
HTR22 Rear HO2S heater (LH) Off/On
°C
IAT IAT sensor
V
INGEAR Load/no load condition Off/On
LOAD Engine load %
LONGFT1 Long term fuel trim (RH) %
LONGFT2 Long term fuel trim (LH) %
g/s
MAF MAF sensor
V
MFF_IAT Intake air temperature at the time of misfire °C
MFF_LOAD Engine load at the time of misfire %
MFF_RNTM Engine running time at time of misfire ms
MFF_RPM Engine speed at the time of misfire RPM
MFF_SOAK Engine off soak time prior to misfire ms
MFF_TP Throttle position at the time of misfire V
MFF_TRIP Number of trips since the time of misfire —
MFF_VSS Vehicle speed at the time of misfire KPH
MIL Malfunction indicator lamp Off/On
MIL_DIS Travelled distance since the MIL illuminated km
O2S11 Front HO2S (RH) V
O2S12 Rear HO2S (RH) V
O2S21 Front HO2S (LH) V
O2S22 Rear HO2S (LH) V
OCTANE Octane of fuel —
PCVHC PCV valve heater control %
PSP Power steering pressure switch Low/High
RO2FT1 Rear HO2S fuel trim (RH) —
RO2FT2 Rear HO2S fuel trim (LH) —
RPM Engine speed RPM
SC_CANCEL Speed control cancel switch Inactive / Active
SC_OFF Cruise control OFF switch Inactive / Active
SC_ON Cruise control ON switch Inactive / Active
SC_RES Cruise resume switch Inactive / Active
SC_SET- Cruise coast switch Inactive / Active
SC_SET+ Cruise set/acceleration switch Inactive / Active
SCCS Speed control command switch V
SHRTFT1 Short term fuel trim (RH) %
SHRTFT11 Front short term fuel trim (RH) %
SHRTFT2 Short term fuel trim (LH) %
SHRTFT21 Front short term fuel trim (LH) %
SPARKADV Ignition timing °
SPKDUR_1 Spark duration of cylinder No.1 sec
SPKDUR_2 Spark duration of cylinder No.2 sec

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ON-BOARD DIAGNOSTIC [MZI-3.5]

PID Name Description Unit
SPKDUR_3 Spark duration of cylinder No.3 sec
SPKDUR_4 Spark duration of cylinder No.4 sec
SPKDUR_5 Spark duration of cylinder No.5 sec
SPKDUR_6 Spark duration of cylinder No.6 sec
SPRK_ACT Actual ignition timing °
TIRESIZE Tire revolution per mile - 01-02
TP REL Relative throttle position %
%
TP1 TP sensor No.1
V
%
TP2 TP sensor No.2
V
VPWR Battery voltage V
VSS Vehicle speed KPH
VT ACT1 Actual valve timing (RH) °
VT ACT2 Actual valve timing (LH) °
VT DIFF1 Difference between target and actual valve timing (RH) °
VT DIFF2 Difference between target and actual valve timing (LH) °
VT DUTY1 Oil control valve duty value (RH) %
VT DUTY2 Oil control valve duty value (LH) %

Diagnostic Monitoring Test Results Access Procedure

1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Powertrain”.
3. Select “OBD Test Modes”.
4. Select “Mode 6 On-Board Test Results”.
• When using the PDS (Pocket PC) DLC-2
1. Select “OBDII Modes”.
2. Select “Mode 6 On-Board Test Results”.
3. Verify the PID data according to the directions on
ac9uuw00001090
the screen.

Simulation Function Procedure

1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “PCM”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “PCM”.
3. Select “DataLogger”.
ac9uuw00001090
3. Select the simulation items from the PID table.
4. Perform the simulation function, inspect the
operations for each parts.
• If there is no operation sound from the relay, motor, and solenoid after the simulation function inspection is
performed, it is possible that there is an open or short circuit in the wiring harness, relay, motor or solenoid,
or sticking and operation malfunction.
End Of Sie

01-02–7
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ON-BOARD DIAGNOSTIC [MZI-3.5]

AFTER REPAIR PROCEDURE [MZI-3.5]
id0102d1801100
1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “PCM”.
5. Select “Retrieve CMDTCs”. DLC-2
• When using the PDS (Pocket PC)
1. Select “Module Tests”.
2. Select “PCM”.
ac9uuw00001450
3. Select “Self Test”.
4. Select “Retrieve CMDTCs”.
3. Verify the DTC according to the directions on the M-MDS screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.
End Of Sie
KOEO/KOER SELF TEST [MZI-3.5]
id0102d1801200
1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “PCM”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “PCM”.
3. Select “Self Test”.
ac9uuw00001451
3. Then, select the “KOEO On Demand Self Test” or
“KOER On Demand Self Test” and perform
procedures according to directions on the M-MDS screen.
4. Verify the DTC according to the directions on the M-MDS screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
5. After completion of repairs, clear all DTCs stored in the PCM, while referring to “AFTER REPAIR
PROCEDURE“.
End Of Sie

01-02–8
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ON-BOARD DIAGNOSTIC [MZI-3.5]

OBD-II DRIVE MODE [MZI-3.5]
id0102d1801300
• The following procedure is designed to execute and complete the OBD-II monitors and to clear the DTC P1000.
• To complete a specific monitor for repair verification, follow Steps 1 through 4, then continue using the steps
indicated by the appropriate monitor.
• The Drive Mode is performed using the M-MDS.

Caution
• While performing the Drive Mode, always operate the vehicle in a safe and lawful manner. 01-02
• When the M-MDS is used to observe monitor system status while driving, be sure to have another
technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD
function and inspect later.

Note
• If the OBD-II system inspection is not completed during the Drive Mode, the following causes are
considered:
— The OBD-II system detects a malfunction.
— The Drive Mode procedure is not completed correctly.
• Disconnecting the battery will reset the memory. Do not disconnect the battery during and after Drive
Mode.
• The M-MDS can be used at anytime through the course of the Drive Mode to monitor the completion
status. Monitoring can be done by viewing the ON BOARD SYSTEM READINESS menu.
• Most OBD-II monitors will complete more readily using a “steady foot” driving style during cruise or
acceleration. Operating the throttle in a "smooth" fashion will minimize the time required for monitor
completion.
• The fuel tank level should be between 1/2 and 3/4 full with 3/4 full being the most desirable.
• The evaporative emission system monitor can only operate during the first 30 min of the engine operation.
When executing the procedure for the evaporative emission system monitor, remain in part throttle
position and drive in a smooth fashion to minimize "fuel slosh".
• When bypassing the EVAP soak times, the PCM must remain powered (ignition switch to the ON position)
after clearing the continuous DTCs and relearning emission diagnostic information.

OBD-II monitor
Step Procedure Purpose
exercised
Drive Mode 1 Note Bypasses the engine soak timer.
Preparation • To bypass the EVAP soak timer (normally 6 Resets the OBD-II monitor status.
hours), the PCM must remain powered after
clearing the continuous DTCs and resetting the
emission monitors information in the PCM.

• Connect the M-MDS to the DLC-2.

• Turn the ignition switch to the ON position (Engine
off).
• Turn the ignition switch off then to the ON position,
(Engine off).
• Select the appropriate vehicle and engine qualifier.
• Clear the continuous DTCs and reset the emission
monitors information in the PCM.

Note
• The following events occur when the
continuous DTCs and the emission monitors
information is cleared from the PCM:
— Clears the number of DTCs and the DTCs.
— Clears the freeze frame data.
— Clears the diagnostic monitoring test
results.
— Clears the status of the OBD-II system
monitors is reset.
— Sets DTC P1000.
2 • Start the engine without turning the ignition switch
off.
3 • Idle the engine for 15 s.
• Drive at 64 km/h {40 mph} until the ECT is 76.7 °C
{170 °F} or more.

01-02–9
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ON-BOARD DIAGNOSTIC [MZI-3.5]

OBD-II monitor
Step Procedure Purpose
exercised
Prep for Monitor 4 Note Engine warm-up and provides IAT input
Entry • When the IAT is not within 4.4—37.8 °C {40—100 to the PCM.
°F} or the altitude is above 2,438 m {8,000 ft},
the EVAP monitor will not run.

• Is the IAT within 4.4—37.8 °C {40—100 °F}?

— If not within the specification, complete the
following steps but, note that step 13 will be
required to "bypass" the EVAP monitor.
HO2S 5 • Cruise at 64 km/h {40 mph} for up to 5 min. Executes the HO2S monitor.
EVAP 6 Note Executes the EVAP emission monitor.
• To initiate the monitor, the throttle should be at
part throttle, Evaporative Emissions Duty Cycle
must be more than 75%, and FLI must be 15—
85%, and for fuel tanks over 25 gallons Fuel
Level Indicator Input must be 30—85%.

• Cruise at 64—89km/h {40—55 mpr} for 10 min.

Catalyst 7 • Stop the vehicle and go to traffic conditions. Executes the catalyst efficiency monitor.
• Include five different constant cruise speeds,
ranging from 32—89 km/h {20—55 mph} over a 10
min period.
CCM (Engine) 8 • Stop the vehicle. Executes the idle air control portion of
• Idle the engine for 2 min with the selector lever in the CCM.
the D range.
CCM (Transaxle) 9 • Stop the vehicle. Executes the transaxle portion of the
• In overdrive, moderately accelerate to 81 km/h {50 CCM.
mph} and cruise for 15 s or more.
• Stop the vehicle and repeat without overdrive to 64
km/h {40 mph} cruising for 30 s or more.
• While at 64 km/h {40 mph}, activate overdrive and
accelerate to 81 km/h {50 mph} and cruise for 15 s
or more.
• Stop the vehicle for 20 s or more.
• Repeat Step 9 five times.
Misfire and Fuel 10 • Stop the vehicle. Allows learning for the misfire monitor.
• Accelerate to 97 km/h {60 mph}.
• Decelerate at closed throttle until reaching 64 km/h
{40 mph} (no brakes).
• Repeat 3 times.
Readiness Check 11 • Access the ON BOARD SYSTEM READINESS to Determines if any monitor has not been
verify the OBD-II monitoring status. completed.
— If completed, all of the OBD-II monitoring status
items change from non-completed to completed.
— If not completed, go to the next step.
Pending Code 12 • Verify that no pending code has been stored. If any Note
Check and EVAP pending code has been stored, perform the • The DTC P1000 will be stored if
Monitor Bypass appropriate DTC inspection. any of the OBD-II monitors does
Check (See 01-02-12 DTC TABLE [MZI-3.5].) not complete.
• Otherwise, return any incomplete monitor.
Determines if a pending code is
Note preventing the clearing of the DTC
• If the EVAP monitor is not completed and the P1000.
IAT was out of the 4.4—37.8 °C {40—100 °F}
range, or the altitude is above 2,438 m
{8,000 ft}, the "EVAP Monitor Bypass“
procedure must be followed.

• Perform the “EVAP Monitor Bypass“ procedure.

EVAP Monitor 13 • Leave the vehicle for 8 h. Allows the “bypass“ counter to
Bypass • Go to Step 2 then perform from Step 2 to 11. increment to two.

End Of Sie

01-02–10
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
DIAGNOSTIC MONITORING TEST RESULTS [MZI-3.5]
id0102d1801400

• The purpose of this test mode is to confirm the result of OBD-II monitor diagnostic test results. The result
values stored when particular monitor is completed are displayed.If the monitor is not completed, initial value is
displayed.
Related
TEST ID Description Unit
system 01-02
10: 01: 01 Front HO2S (RH) Switchpoint V
10: 01: 80 Front HO2S (RH) Voltage Amplitude V
10: 01: 81 Front HO2S (RH) Heater Current A
10: 05: 01 Front HO2S (LH) Switchpoint V
10: 05: 80 Front HO2S (LH) Voltage Amplitude V
HO2S
10: 05: 81 Front HO2S (LH) Heater Current A
10: 02: 01 Rear HO2S (RH) Switchpoint V
10: 02: 81 Rear HO2S (RH) Heater Current A
10: 06: 01 Rear HO2S (LH) Switchpoint V
10: 06: 81 Rear HO2S (LH) Heater Current A
10: 21: 80 —
HO2S (Front) and HO2S (Rear) switching time ratio Catalyst
10: 22: 80 —
10: 3A: 80 Phase 0 Excessive vacuum limit Pa
10: 3A: 81 Phase 4 Purge Valve stuck open limit Pa
10: 3A: 82 Phase 0 Gross Leak Limit EVAP Pa
Phase 2 0.040" leak check vacuum bleedup and maximum 0.040" leak
10: 3B: 80 Pa
threshold
10: A1: 80 Type A Misfire Rate (engine 200 rpm) %
10: A1: 81 Type B Misfire Rate (engine 1000 rpm) %
10: A1: 82 Highest Misfire Rate Type A (engine 200 rpm) %
10: A1: 83 Highest Misfire Rate Type B (engine 1000 rpm) %
10: A1: 84 Inferred Catalyst Mid-Bed Temperature °C
10: A2: 0B Cylinder No.1 average misfire counts for last 10 DC —
10: A2: 0C Cylinder No.1 misfire counts for last/current DC —
10: A2: 80 Cylinder No.1 Type A Misfire Rate (engine 200 rpm) %
10: A2: 81 Cylinder No.1 Type B Misfire Rate (engine 1000 rpm) %
10: A3: 0B Cylinder No.2 average misfire counts for last 10 DC —
10: A3: 0C Cylinder No.2 misfire counts for last/current DC —
10: A3: 80 Cylinder No.2 Type A Misfire Rate (engine 200 rpm) %
10: A3: 81 Cylinder No.2 Type B Misfire Rate (engine 1000 rpm) %
10: A4: 0B Cylinder No.3 average misfire counts for last 10 DC —
10: A4: 0C Cylinder No.3 misfire counts for last/current DC Misfire —
10: A4: 80 Cylinder No.3 Type A Misfire Rate (engine 200 rpm) %
10: A4: 81 Cylinder No.3 Type B Misfire Rate (engine 1000 rpm) %
10: A5: 0B Cylinder No.4 average misfire counts for last 10 DC —
10: A5: 0C Cylinder No.4 misfire counts for last/current DC —
10: A5: 80 Cylinder No.4 Type A Misfire Rate (engine 200 rpm) %
10: A5: 81 Cylinder No.4 Type B Misfire Rate (engine 1000 rpm) %
10: A6: 0B Cylinder No.5 average misfire counts for last 10 DC —
10: A6: 0C Cylinder No.5 misfire counts for last/current DC —
10: A6: 80 Cylinder No.5 Type A Misfire Rate (engine 200 rpm) %
10: A6: 81 Cylinder No.5 Type B Misfire Rate (engine 1000 rpm) %
10: A7: 0B Cylinder No.6 average misfire counts for last 10 DC —
10: A7: 0C Cylinder No.6 misfire counts for last/current DC —
10: A7: 80 Cylinder No.6 Type A Misfire Rate (engine 200 rpm) %
10: A7: 81 Cylinder No.6 Type B Misfire Rate (engine 1000 rpm) %

End Of Sie

01-02–11
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
DTC TABLE [MZI-3.5]
id0102d1801500

DTC Description MIL DC Page

B1342 PCM malfunction OFF — (See 01-02-17 DTC B1342 [MZI-3.5].)
P0010 CMP actuator circuit open (RH) ON 2 (See 01-02-18 DTC P0010 [MZI-3.5].)
P0011 CMP timing over-advanced (RH) ON 2 (See 01-02-20 DTC P0011 [MZI-3.5].)
P0012 CMP timing over-retarded (RH) ON 2 (See 01-02-21 DTC P0012 [MZI-3.5].)
(See 01-02-22 DTC P0016, P0018 [MZI-
P0016 CKP-CMP sensor (RH) correlation ON 2
3.5].)
(See 01-02-22 DTC P0016, P0018 [MZI-
P0018 CKP-CMP sensor (LH) correlation ON 2
3.5].)
P0020 CMP actuator circuit open (LH) ON 2 (See 01-02-23 DTC P0020 [MZI-3.5].)
P0021 CMP timing over-advanced (LH) ON 2 (See 01-02-25 DTC P0021 [MZI-3.5].)
P0022 CMP timing over-retarded (LH) ON 2 (See 01-02-26 DTC P0022 [MZI-3.5].)
(See 01-02-27 DTC P0040, P0041 [MZI-
P0040 Front HO2S (LH/RH) signals swapped OFF 1
3.5].)
(See 01-02-27 DTC P0040, P0041 [MZI-
P0041 Rear HO2S (LH/RH) signals swapped OFF 1
3.5].)
(See 01-02-27 DTC P0053, P0054,
P0053 Front HO2S (RH) heater resistance ON 2
P0059, P0060 [MZI-3.5].)
(See 01-02-27 DTC P0053, P0054,
P0054 Rear HO2S (RH) heater resistance ON 2
P0059, P0060 [MZI-3.5].)
(See 01-02-27 DTC P0053, P0054,
P0059 Front HO2S (LH) heater resistance ON 2
P0059, P0060 [MZI-3.5].)
(See 01-02-27 DTC P0053, P0054,
P0060 Rear HO2S (LH) heater resistance ON 2
P0059, P0060 [MZI-3.5].)
P0068 MAP/MAF-throttle position correlation ON 2 (See 01-02-30 DTC P0068 [MZI-3.5].)
P0102 MAF circuit low input ON 2 (See 01-02-32 DTC P0102 [MZI-3.5].)
P0103 MAF circuit high input ON 2 (See 01-02-34 DTC P0103 [MZI-3.5].)
P0104 MAF circuit intermittent/erratic OFF 1 (See 01-02-36 DTC P0104 [MZI-3.5].)
P0111 IAT sensor circuit range/performance ON 2 (See 01-02-38 DTC P0111 [MZI-3.5].)
P0112 IAT sensor circuit low input ON 2 (See 01-02-39 DTC P0112 [MZI-3.5].)
P0113 IAT sensor circuit high input ON 2 (See 01-02-41 DTC P0113 [MZI-3.5].)
P0114 IAT sensor Intermittent/erratic OFF 1 (See 01-02-43 DTC P0114 [MZI-3.5].)
P0116 CHT sensor circuit range/performance ON 2 (See 01-02-44 DTC P0116 [MZI-3.5].)
P0119 CHT sensor circuit intermittent/erratic OFF 1 (See 01-02-45 DTC P0119 [MZI-3.5].)
P0122 TP sensor No.1 circuit low input ON*2 2 (See 01-02-46 DTC P0122 [MZI-3.5].)
P0123 TP sensor No.1 circuit high input ON*2 2 (See 01-02-48 DTC P0123 [MZI-3.5].)
Coolant thermostat (coolant temp below thermostat
P0128 ON 2 (See 01-02-50 DTC P0128 [MZI-3.5].)
regulating temperature)
(See 01-02-51 DTC P0132, P0138,
P0132 Front HO2S (RH) circuit high voltage ON 2
P0152, P0158 [MZI-3.5].)
(See 01-02-53 DTC P0133, P0139,
P0133 Front HO2S (RH) circuit slow response ON 2
P0153, P0159 [MZI-3.5].)
(See 01-02-58 DTC P0135, P0141,
P0135 Front HO2S (RH) heater circuit ON 2
P0155, P0161 [MZI-3.5].)
(See 01-02-51 DTC P0132, P0138,
P0138 Rear HO2S (RH) circuit high voltage ON 2
P0152, P0158 [MZI-3.5].)
(See 01-02-53 DTC P0133, P0139,
P0139 Rear HO2S (RH) circuit slow response ON 2
P0153, P0159 [MZI-3.5].)
(See 01-02-58 DTC P0135, P0141,
P0141 Rear HO2S (RH) heater circuit ON 2
P0155, P0161 [MZI-3.5].)
P0148 Fuel delivery error OFF 1 (See 01-02-62 DTC P0148 [MZI-3.5].)
(See 01-02-51 DTC P0132, P0138,
P0152 Front HO2S (LH) circuit high voltage ON 2
P0152, P0158 [MZI-3.5].)
(See 01-02-53 DTC P0133, P0139,
P0153 Front HO2S (LH) circuit slow response ON 2
P0153, P0159 [MZI-3.5].)
(See 01-02-58 DTC P0135, P0141,
P0155 Front HO2S (LH) heater circuit ON 2
P0155, P0161 [MZI-3.5].)

01-02–12 Revised 2/2007 (Ref. No. R031/07)

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
DTC Description MIL DC Page
(See 01-02-51 DTC P0132, P0138,
P0158 Rear HO2S (LH) circuit high voltage ON 2
P0152, P0158 [MZI-3.5].)
(See 01-02-53 DTC P0133, P0139,
P0159 Rear HO2S (LH) circuit slow response ON 2
P0153, P0159 [MZI-3.5].)
(See 01-02-58 DTC P0135, P0141,
P0161 Rear HO2S (LH) heater circuit ON 2
P0155, P0161 [MZI-3.5].)
(See 01-02-65 DTC P0171, P0174 [MZI- 01-02
P0171 System too lean (RH) ON 2
3.5].)
(See 01-02-69 DTC P0172, P0175 [MZI-
P0172 System too rich (RH) ON 2
3.5].)
(See 01-02-65 DTC P0171, P0174 [MZI-
P0174 System too lean (LH) ON 2
3.5].)
(See 01-02-69 DTC P0172, P0175 [MZI-
P0175 System too rich (LH) ON 2
3.5].)
P0201 Injector circuit/open—cylinder No.1 ON 2 (See 01-02-71 DTC P0201 [MZI-3.5].)
P0202 Injector circuit/open—cylinder No.2 ON 2 (See 01-02-73 DTC P0202 [MZI-3.5].)
P0203 Injector circuit/open—cylinder No.3 ON 2 (See 01-02-75 DTC P0203 [MZI-3.5].)
P0204 Injector circuit/open—cylinder No.4 ON 2 (See 01-02-77 DTC P0204 [MZI-3.5].)
P0205 Injector circuit/open—cylinder No.5 ON 2 (See 01-02-79 DTC P0205 [MZI-3.5].)
P0206 Injector circuit/open—cylinder No.6 ON 2 (See 01-02-81 DTC P0206 [MZI-3.5].)
P0222 TP sensor No.2 circuit low input ON*2 2 (See 01-02-83 DTC P0222 [MZI-3.5].)
P0223 TP sensor No.2 circuit high input ON*2 2 (See 01-02-85 DTC P0223 [MZI-3.5].)
P0230 FP primary circuit OFF 1 (See 01-02-87 DTC P0230 [MZI-3.5].)
P0231 FP secondary circuit low OFF 1 (See 01-02-89 DTC P0231 [MZI-3.5].)
P0232 FP secondary circuit high OFF 1 (See 01-02-91 DTC P0232 [MZI-3.5].)
P0297 Vehicle over speed condition OFF 1 (See 01-02-93 DTC P0297 [MZI-3.5].)
P0300 Random misfire detected ON 1 (See 01-02-94 DTC P0300 [MZI-3.5].)
(See 01-02-97 DTC P0301, P0302,
P0301 Cylinder No.1 misfire detected ON 1 P0303, P0304, P0305, P0306, P0316
[MZI-3.5].)
(See 01-02-97 DTC P0301, P0302,
P0302 Cylinder No.2 misfire detected ON 1 P0303, P0304, P0305, P0306, P0316
[MZI-3.5].)
(See 01-02-97 DTC P0301, P0302,
P0303 Cylinder No.3 misfire detected ON 1 P0303, P0304, P0305, P0306, P0316
[MZI-3.5].)
(See 01-02-97 DTC P0301, P0302,
P0304 Cylinder No.4 misfire detected ON 1 P0303, P0304, P0305, P0306, P0316
[MZI-3.5].)
(See 01-02-97 DTC P0301, P0302,
P0305 Cylinder No.5 misfire detected ON 1 P0303, P0304, P0305, P0306, P0316
[MZI-3.5].)
(See 01-02-97 DTC P0301, P0302,
P0306 Cylinder No.6 misfire detected ON 1 P0303, P0304, P0305, P0306, P0316
[MZI-3.5].)
P0315 CKP system variation not learned ON 2 (See 01-02-100 DTC P0315 [MZI-3.5].)
(See 01-02-97 DTC P0301, P0302,
P0316 Misfire detected on startup (first 1000 revolutions) OFF 1 P0303, P0304, P0305, P0306, P0316
[MZI-3.5].)
P0320 Ignition/distributor engine speed input circuit ON 2 (See 01-02-101 DTC P0320 [MZI-3.5].)
P0325 KS circuit (RH) OFF 1 (See 01-02-104 DTC P0325 [MZI-3.5].)
P0330 KS circuit (LH) OFF 1 (See 01-02-106 DTC P0330 [MZI-3.5].)
P0340 CMP sensor (RH) circuit ON 2 (See 01-02-108 DTC P0340 [MZI-3.5].)
P0344 CMP sensor (RH) circuit intermittent ON 2 (See 01-02-111 DTC P0344 [MZI-3.5].)
P0345 CMP sensor (LH) circuit ON 2 (See 01-02-114 DTC P0345 [MZI-3.5].)
P0349 CMP sensor (LH) circuit intermittent ON 2 (See 01-02-117 DTC P0349 [MZI-3.5].)
(See 01-02-119 DTC P0351, 0352,
P0351 Ignition coil No.1 primary/secondary circuit ON 2
0353, 0354, 0355, 0356 [MZI-3.5].)

Revised 2/2007 (Ref. No. R031/07) 01-02–13

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
DTC Description MIL DC Page
(See 01-02-119 DTC P0351, 0352,
P0352 Ignition coil No.2 primary/secondary circuit ON 2
0353, 0354, 0355, 0356 [MZI-3.5].)
(See 01-02-119 DTC P0351, 0352,
P0353 Ignition coil No.3 primary/secondary circuit ON 2
0353, 0354, 0355, 0356 [MZI-3.5].)
(See 01-02-119 DTC P0351, 0352,
P0354 Ignition coil No.4 primary/secondary circuit ON 2
0353, 0354, 0355, 0356 [MZI-3.5].)
(See 01-02-119 DTC P0351, 0352,
P0355 Ignition coil No.5 primary/secondary circuit ON 2
0353, 0354, 0355, 0356 [MZI-3.5].)
(See 01-02-119 DTC P0351, 0352,
P0356 Ignition coil No.6 primary/secondary circuit ON 2
0353, 0354, 0355, 0356 [MZI-3.5].)
(See 01-02-122 DTC P0420, P0430
P0420 Catalyst system efficiency below threshold (RH) ON 2
[MZI-3.5].)
(See 01-02-122 DTC P0420, P0430
P0430 Catalyst system efficiency below threshold (LH) ON 2
[MZI-3.5].)
(See 01-02-123 DTC P0442, P0456
P0442 Evaporative emission system leak detected (small leak) ON 2
[MZI-3.5].)
P0443 Purge solenoid valve circuit ON 2 (See 01-02-126 DTC P0443 [MZI-3.5].)
P0446 CV solenoid valve control circuit ON 2 (See 01-02-128 DTC P0446 [MZI-3.5].)
P0451 Fuel tank pressure sensor range/performance ON 2 (See 01-02-130 DTC P0451 [MZI-3.5].)
P0452 Fuel tank pressure sensor low input ON 2 (See 01-02-131 DTC P0452 [MZI-3.5].)
P0453 Fuel tank pressure sensor high input ON 2 (See 01-02-133 DTC P0453 [MZI-3.5].)
P0454 Fuel tank pressure sensor intermittent ON 2 (See 01-02-135 DTC P0454 [MZI-3.5].)
Evaporative emission system leak detected (gross leak/no
P0455 ON 2 (See 01-02-136 DTC P0455 [MZI-3.5].)
flow)
Evaporative emission system leak detected (very small (See 01-02-123 DTC P0442, P0456
P0456 ON 1
leak) [MZI-3.5].)
Evaporative emission system leak detected (fuel cap
P0457
loose/off) OFF*1 1 (See 01-02-138 DTC P0457 [MZI-3.5].)
P0460 Fuel level sensor circuit ON 2 (See 01-02-139 DTC P0460 [MZI-3.5].)
P0461 Fuel gauge sender unit range/performance problem ON 2 (See 01-02-140 DTC P0461 [MZI-3.5].)
P0462 Fuel gauge sender unit circuit low input ON 2 (See 01-02-141 DTC P0462 [MZI-3.5].)
P0463 Fuel gauge sender unit circuit high input ON 2 (See 01-02-141 DTC P0463 [MZI-3.5].)
P0480 Fan control circuit OFF 1 (See 01-02-142 DTC P0480 [MZI-3.5].)
P0505 Idle speed control system problem OFF 1 (See 01-02-145 DTC P0505 [MZI-3.5].)
P0506 IAC system RPM lower than expected ON 2 (See 01-02-147 DTC P0506 [MZI-3.5].)
P0507 IAC system RPM higher than expected ON 2 (See 01-02-148 DTC P0507 [MZI-3.5].)
P050E Cold start engine exhaust temperature out of range ON 2 (See 01-02-148 DTC P050E [MZI-3.5].)
P053A PCV valve heater control circuit/open OFF 1 (See 01-02-150 DTC P053A [MZI-3.5].)
Cruise control multi-function input circuit range/
P0579 OFF 1 (See 01-02-154 DTC P0579 [MZI-3.5].)
performance
P0581 Cruise control multi-function input circuit high OFF 1 (See 01-02-156 DTC P0581 [MZI-3.5].)
P0600 Serial communication link OFF*2 1 (See 01-02-158 DTC P0600 [MZI-3.5].)
P0602 PCM programming error ON 2 (See 01-02-159 DTC P0602 [MZI-3.5].)
P0603 PCM keep alive memory (KAM) error ON 2 (See 01-02-160 DTC P0603 [MZI-3.5].)
Internal control module random access memory (RAM)
P0604 ON 2 (See 01-02-162 DTC P0604 [MZI-3.5].)
error
P0605 PCM read only memory (ROM) error ON 2 (See 01-02-162 DTC P0605 [MZI-3.5].)
P0606 ECM/PCM processor ON 2 (See 01-02-163 DTC P0606 [MZI-3.5].)
P0607 Control module performance ON 2 (See 01-02-164 DTC P0607 [MZI-3.5].)
(See 01-02-164 DTC P060A, P060C,
P060A Internal control module monitoring processor performance OFF*2 1
P061D [MZI-3.5].)
P060B Internal control module A/D processing performance ON*2 2 (See 01-02-165 DTC P060B [MZI-3.5].)
(See 01-02-164 DTC P060A, P060C,
P060C Internal control module main processor performance ON*2 2
P061D [MZI-3.5].)
P0610 Control module vehicle options error ON 2 (See 01-02-166 DTC P0610 [MZI-3.5].)
P061B Internal control module torque calculation performance ON*2 2 (See 01-02-167 DTC P061B [MZI-3.5].)
P061C Internal control module engine RPM performance ON*2 2 (See 01-02-168 DTC P061C [MZI-3.5].)

01-02–14 Revised 2/2007 (Ref. No. R031/07)

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
DTC Description MIL DC Page
(See 01-02-164 DTC P060A, P060C,
P061D Internal control module engine air mass performance ON*2 2 P061D [MZI-3.5].)
Internal control module throttle actuator controller
P061F performance ON*2 2 (See 01-02-169 DTC P061F [MZI-3.5].)
P0620 Generator control circuit OFF 1 (See 01-02-170 DTC P0620 [MZI-3.5].)
P0625 Generator field terminal circuit low OFF 1 (See 01-02-172 DTC P0625 [MZI-3.5].)
P0626 Generator field terminal circuit high OFF 1 (See 01-02-174 DTC P0626 [MZI-3.5].) 01-02
P0642 Sensor reference voltage circuit low ON 2 (See 01-02-176 DTC P0642 [MZI-3.5].)
P0643 Sensor reference voltage circuit high ON 2 (See 01-02-178 DTC P0643 [MZI-3.5].)
P0645 A/C relay control circuit OFF 1 (See 01-02-180 DTC P0645 [MZI-3.5].)
P0685 ECM/PCM power relay control circuit/open OFF 1 (See 01-02-183 DTC P0685 [MZI-3.5].)
P0689 ECM/PCM power relay sense circuit low OFF 1 (See 01-02-185 DTC P0689 [MZI-3.5].)
P0690 ECM/PCM power relay sense circuit high OFF 1 (See 01-02-187 DTC P0690 [MZI-3.5].)
P1000 OBD II systems readiness test not complete OFF 1 (See 01-02-189 DTC P1000 [MZI-3.5].)
P1001 KOER not able to complete, KOER aborted OFF 1 (See 01-02-190 DTC P1001 [MZI-3.5].)
P1101 MAF sensor out of self-test range OFF 1 (See 01-02-191 DTC P1101 [MZI-3.5].)
Exhaust temperature out of range, HO2S tests not
P1127 OFF 1 (See 01-02-193 DTC P1127 [MZI-3.5].)
completed
Throttle actuator control throttle body air flow trim at max
P115E OFF 1 (See 01-02-194 DTC P115E [MZI-3.5].)
limit
P1260 Theft detected, vehicle immobilized OFF 1 (See 01-02-195 DTC P1260 [MZI-3.5].)
(See 01-02-196 DTC P1285, P1299
P1285 Cylinder head over temperature condition OFF 1 [MZI-3.5].)
P1288 CHT sensor out of self-test range OFF 1 (See 01-02-198 DTC P1288 [MZI-3.5].)
P1289 CHT sensor circuit high input ON 2 (See 01-02-199 DTC P1289 [MZI-3.5].)
P1290 CHT sensor circuit low input ON 2 (See 01-02-201 DTC P1290 [MZI-3.5].)
(See 01-02-196 DTC P1285, P1299
P1299 Cylinder head over temperature protection active ON 1 [MZI-3.5].)
P1336 CKP/CMP sensor range/performance ON 2 (See 01-02-202 DTC P1336 [MZI-3.5].)
P1397 System voltage out of self-test range OFF 1 (See 01-02-204 DTC P1397 [MZI-3.5].)
P1450 Unable to bleed up fuel tank vacuum ON 2 (See 01-02-204 DTC P1450 [MZI-3.5].)
P145E PCV heater control circuit OFF 1 (See 01-02-206 DTC P145E [MZI-3.5].)
P1464 A/C demand out of self-test range OFF 1 (See 01-02-209 DTC P1464 [MZI-3.5])
P1500 Vehicle speed signal OFF 1 (See 01-02-210 DTC P1500 [MZI-3.5])
P1501 Vehicle speed sensor (VSS) out of self-test range OFF 1 (See 01-02-211 DTC P1501 [MZI-3.5].)
P1633 Keep alive power voltage too low ON 1 (See 01-02-212 DTC P1633 [MZI-3.5].)
P1635 Tire/axle out of acceptable range OFF 1 (See 01-02-213 DTC P1635 [MZI-3.5].)
P1639 Vehicle ID block corrupted, not programmed ON 2 (See 01-02-214 DTC P1639 [MZI-3.5].)
P1650 PSP switch out of self-test range OFF 1 (See 01-02-214 DTC P1650 [MZI-3.5].)
P1674 Control module software corrupted OFF*2 1 (See 01-02-216 DTC P1674 [MZI-3.5].)
P1703 Brake switch out of self-test range OFF 1 (See 01-02-217 DTC P1703 [MZI-3.5].)
P2100 Throttle actuator circuit open OFF*2 1 (See 01-02-219 DTC P2100 [MZI-3.5].)
P2101 Throttle actuator circuit range/performance ON*2 2 (See 01-02-221 DTC P2101 [MZI-3.5].)
(See 01-02-222 DTC P2104, P2105,
P2104 Throttle actuator control system - forced idle ON*2 2 P2110 [MZI-3.5].)
(See 01-02-222 DTC P2104, P2105,
P2105 Throttle actuator control system - forced engine shutdown OFF*2 1 P2110 [MZI-3.5].)
P2107 Throttle actuator control module processor ON*2 2 (See 01-02-223 DTC P2107 [MZI-3.5].)
(See 01-02-222 DTC P2104, P2105,
P2110 Throttle actuator control system - forced limited RPM ON*2 2 P2110 [MZI-3.5].)
P2111 Throttle actuator control system - stuck open ON*2 2 (See 01-02-225 DTC P2111 [MZI-3.5].)
P2112 Throttle actuator control system - stuck closed ON*2 2 (See 01-02-228 DTC P2112 [MZI-3.5].)
(See 01-02-230 DTC P2121, P2126,
P2121 APP sensor No.1 circuit range/performance OFF*2 1 P2131 [MZI-3.5].)
P2122 APP sensor No.1 circuit low input OFF*2 1 (See 01-02-234 DTC P2122 [MZI-3.5].)
P2123 APP sensor No.1 circuit high input OFF*2 1 (See 01-02-236 DTC P2123 [MZI-3.5].)
Revised 2/2007 (Ref. No. R031/07) 01-02–15
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
DTC Description MIL DC Page
(See 01-02-230 DTC P2121, P2126,
P2126 APP sensor No.2 circuit range/performance OFF*2 1
P2131 [MZI-3.5].)
P2127 APP sensor No.2 circuit low input OFF*2 1 (See 01-02-238 DTC P2127 [MZI-3.5].)
P2128 APP sensor No.2 circuit high input OFF*2 1 (See 01-02-240 DTC P2128 [MZI-3.5].)
(See 01-02-230 DTC P2121, P2126,
P2131 APP sensor No.3 circuit range/performance OFF*2 1
P2131 [MZI-3.5].)
P2132 APP sensor No.3 circuit low input OFF*2 1 (See 01-02-242 DTC P2132 [MZI-3.5].)
P2133 APP sensor No.3 circuit high input OFF*2 1 (See 01-02-244 DTC P2133 [MZI-3.5].)
P2135 TP sensor No.1/No.2 voltage correlation ON*2 2 (See 01-02-246 DTC P2135 [MZI-3.5].)
(See 01-02-248 DTC P2195, P2197
P2195 Front HO2S (RH) signal stuck lean ON 2
[MZI-3.5].)
(See 01-02-250 DTC P2196, P2198
P2196 Front HO2S (RH) signal stuck rich ON 2
[MZI-3.5].)
(See 01-02-248 DTC P2195, P2197
P2197 Front HO2S (LH) signal stuck lean ON 2
[MZI-3.5].)
(See 01-02-250 DTC P2196, P2198
P2198 Front HO2S (LH) signal stuck rich ON 2
[MZI-3.5].)
(See 01-02-252 DTC P2270, P2272
P2270 Rear HO2S (RH) signal stuck lean ON 2
[MZI-3.5].)
(See 01-02-253 DTC P2271, P2273
P2271 Rear HO2S (RH) signal stuck rich ON 2
[MZI-3.5].)
(See 01-02-252 DTC P2270, P2272
P2272 Rear HO2S (LH) signal stuck lean ON 2
[MZI-3.5].)
(See 01-02-253 DTC P2271, P2273
P2273 Rear HO2S (LH) signal stuck rich ON 2
[MZI-3.5].)
Evaporative emission system monitoring processor
P260F ON 2 (See 01-02-254 DTC P260F [MZI-3.5].)
performance
U0101 Communication error to TCM
U0129 Communication error to DSC/RSC HU/CM (See 09-02L-10 PROCEDURES FOR DETERMINING
THE LOCATION OF A MALFUNCTION [MULTIPLEX
U0155 Communication error to instrument cluster
COMMUNICATION SYSTEM].)
U0300*2 Internal control module software incompatibility

*1 : The fuel cap warning light illuminates.

*2 : The electronic throttle control (ETC) warning light illuminates.

End Of Sie
SOKYU_WM: DTC P00XX

01-02–16 Revised 2/2007 (Ref. No. R031/07)

1890-1U-06H(01-02).fm 17 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC B1342 [MZI-3.5]
id0102d1815700

DTC B1342 PCM malfunction

DETECTION
• Malfunction in the PCM internal circuit.
CONDITION
POSSIBLE • PCM EEPROM malfunction
CAUSE • PCM parameter reset has not been completed
01-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY CURRENT STATUS OF Yes Replace the PCM, then go to the next step.
MALFUNCTION (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Clear the DTC from the PCM memory using No Go to the next step.
the M-MDS.
• Perform the PCM parameter reset using the
M-MDS.
(See 09-14-19 IMMOBILIZER SYSTEM
COMPONENT REPLACEMENT/KEY
ADDITION AND CLEARING [ADVANCED
KEYLESS SYSTEM].) (See 09-14-37
IMMOBILIZER SYSTEM COMPONENT
REPLACEMENT/KEY ADDITION AND
CLEARING [KEYLESS ENTRY SYSTEM].)
• Is same DTC present?
2 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR (See 01-02-12 DTC TABLE [MZI-3.5].)
PROCEDURE”. No Troubleshooting completed.
(See 01-02-8 AFTER REPAIR PROCEDURE
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–17
1890-1U-06H(01-02).fm 18 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0010 [MZI-3.5]
id0102d1877700

DTC P0010 CMP actuator circuit open (RH)

DETECTION • The PCM monitors the OCV (RH) circuit to the PCM for high and low voltage. The test fails if the voltage
CONDITION exceeds or falls below a calibrated limit for a calibrated amount of time.
• OCV (RH) malfunction
• Connector or terminal malfunction
POSSIBLE • Open circuit between OCV (RH) terminal A and main relay No.1 terminal D
CAUSE • Open circuit between OCV (RH) terminal B and PCM terminal 2BP
• Short to ground circuit between OCV (RH) terminal B and PCM terminal 2BP
• Short to power supply between OCV (RH) terminal B and PCM terminal 2BP
OCV (RH) MAIN RELAY NO.1 PCM

3 5
A

4
3 6 7 9 8
B 2BP

PCM
WIRING HARNESS-SIDE CONNECTOR
OCV (RH)
MAIN RELAY NO.1 WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C
A E

C 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
A
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D
D B
2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then
• Has FREEZE FRAME DATA been recorded? go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT OCV (RH) CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the OCV (RH) connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–18
1890-1U-06H(01-02).fm 19 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT OCV (RH) Yes Replace the OCV (RH), then go to Step 10.
• Inspect the OCV (RH). (See 01-10-55 OIL CONTROL VALVE (OCV)
(See 01-10-55 OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
5 INSPECT OCV (RH) CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 10. 01-02
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the OCV (RH)
connector terminal A and body ground.
• Is the voltage B+?
6 INSPECT OCV (RH) CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to Step 10.
POWER SUPPLY No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the OCV (RH)
connector terminal B (wiring harness-side) and
body ground.
• Is the voltage B+?
7 INSPECT OCV (RH) CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to Step 10.
GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between OCV (RH)
terminal B (wiring harness-side) and body
ground.
• Is there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
9 INSPECT OCV (RH) CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to the next
• Turn the ignition switch off. step.
• Measure the resistance between the OCV (RH)
connector terminal B (wiring harness-side) and
PCM terminal 2BP (wiring harness-side).
• Is there continuity?
10 VERIFY TROUBLESHOOTING OF DTC P0010 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using the
M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–19
1890-1U-06H(01-02).fm 20 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0011 [MZI-3.5]
id0102d1801600

DTC P0011 CMP timing over-advanced (RH)

DETECTION • The PCM monitors the variable valve timing position for an over-advanced camshaft timing. The test fails
CONDITION when the camshaft timing exceeds a maximum calibrated value or remains in an advanced position.
• OCV (RH) malfunction
POSSIBLE
• Spool valve in OCV (RH) is stuck in advanced position
CAUSE
• Improper valve timing due to timing chain slippage

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY TIMING CHAIN INSTALLATION Yes Go to the next step.
• Stop the engine. No Reinstall the timing chain, then go to Step 5.
• Remove the front cover.
• Is the camshaft timing mark at the correct
point?
(See 01-10-11 TIMING CHAIN REMOVAL/
INSTALLATION [MZI-3.5].)
4 INSPECT OCV (RH) Yes Replace the OCV (RH), then go to the next step.
• Inspect the OCV (RH). (See 01-10-55 OIL CONTROL VALVE (OCV) REMOVAL/
(See 01-10-55 OIL CONTROL VALVE (OCV) INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
5 VERIFY TROUBLESHOOTING OF DTC P0011 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Turn the ignition switch off.
• Start the engine and warm it up completely.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–20
1890-1U-06H(01-02).fm 21 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0012 [MZI-3.5]
id0102d1801700

DTC P0012 CMP timing over-retarded (RH)

DETECTION • The PCM monitors the variable valve timing position for over-retarded camshaft timing. The test fails when
CONDITION the camshaft timing exceeds a maximum calibrated value or remains in a retarded position.
• OCV (RH) malfunction
POSSIBLE • Low engine oil pressure
CAUSE • Spool valve in the OCV (RH) is stuck in retard position 01-02
• Improper valve timing due to timing chain slippage

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY ENGINE OIL PRESSURE Yes Inspect the engine oil pressure, then go to Step 6.
• Start the engine. (See 01-11-3 OIL PRESSURE INSPECTION [MZI-3.5].)
• Does the oil pressure warning light illuminate? No Go to the next step.
4 VERIFY TIMING CHAIN INSTALLATION Yes Go to the next step.
• Stop the engine. No Reinstall the timing chain, then go to Step 6.
• Remove the front cover.
• Is the camshaft timing mark at the correct
point?
(See 01-10-11 TIMING CHAIN REMOVAL/
INSTALLATION [MZI-3.5].)
5 INSPECT OCV (RH) Yes Replace the OCV (RH), then go to the next step.
• Inspect the OCV (RH). No Go to the next step.
(See 01-10-55 OIL CONTROL VALVE (OCV)
INSPECTION [MZI-3.5].)
• Is there any malfunction?
6 VERIFY TROUBLESHOOTING OF DTC P0012 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Turn the ignition switch off.
• Start the engine and warm it up completely.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–21
1890-1U-06H(01-02).fm 22 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0016, P0018 [MZI-3.5]
id0102d1953600

DTC P0016 P0016: CKP-CMP sensor (RH) correlation

DTC P0018 P0018: CKP-CMP sensor (LH) correlation
DETECTION • The PCM monitors the variable valve timing position for a misalignment between the camshaft and
CONDITION crankshaft. The test fails when the misalignment is more than 1 tooth.
• OCV malfunction
POSSIBLE
• Camshaft advanced mechanism binding
CAUSE
• Improper valve timing

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING AND STORED Yes Go to the appropriate DTC troubleshooting.
DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off, then to the ON No Go to the next step.
position (Engine off)
• Verify pending and stored DTCs using M-MDS.
• Is other DTC present?
4 VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to the next step.
• Start the engine and warm up completely. No Replace the OCV, then go to Step 6.
• Access VT ACT1 (P0016) or VT ACT2 (P0018) (See 01-10-55 OIL CONTROL VALVE (OCV) REMOVAL/
PID using the M-MDS. INSTALLATION [MZI-3.5].)
• Is PID reading normal?
— -14—-46 °
5 VERIFY TIMING CHAIN INSTALLATION Yes Go to the next step.
• Stop the engine. No Reinstall the timing chain, then go to the next step.
• Remove the front cover.
• Is the camshaft timing mark at the correct
point?
(See 01-10-11 TIMING CHAIN REMOVAL/
INSTALLATION [MZI-3.5].)
6 VERIFY TROUBLESHOOTING OF DTC P0016, Yes Replace the PCM, then go to the next step.
P0018 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Turn the engine switch to the ON position.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–22
1890-1U-06H(01-02).fm 23 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0020 [MZI-3.5]
id0102d1970000

DTC P0020 CMP actuator circuit open (LH)

DETECTION • The PCM monitors the OCV (LH) circuit to the PCM for high and low voltage. The test fails if the voltage
CONDITION exceeds or falls below a calibrated limit for a calibrated amount of time.
• OCV (LH) malfunction
• Connector or terminal malfunction
POSSIBLE • Open circuit between OCV (LH) terminal A and main relay No.1 terminal D 01-02
CAUSE • Open circuit between OCV (LH) terminal B and PCM terminal 2BK
• Short to ground circuit between OCV (LH) terminal B and PCM terminal 2BK
• Short to power supply between OCV (LH) terminal B and PCM terminal 2BK
OCV (LH) MAIN RELAY NO.1 PCM

3 5
A

4
3 6 7 9 8
B 2BK

PCM
WIRING HARNESS-SIDE CONNECTOR
OCV (LH)
MAIN RELAY NO.1 WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C
A E

C 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
A
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D
D B
2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then
• Has FREEZE FRAME DATA been recorded? go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT OCV (LH) CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the OCV (LH) connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–23
1890-1U-06H(01-02).fm 24 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT OCV (LH) Yes Replace the OCV (LH), then go to Step 10.
• Inspect the OCV (LH). (See 01-10-55 OIL CONTROL VALVE (OCV)
(See 01-10-55 OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
5 INSPECT OCV (LH) CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the OCV (LH)
connector terminal A (wiring harness-side) and
body ground.
• Is the voltage B+?
6 INSPECT OCV (LH) CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to Step 10.
POWER SUPPLY No Go to the next step.
• Disconnect the PCM connector.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the OCV (LH)
connector terminal B and body ground.
• Is the voltage B+?
7 INSPECT OCV (LH) CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to Step 10.
GROUND No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect for continuity between OCV (LH)
terminal B (wiring harness-side) and body
ground.
• Is there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
9 INSPECT OCV (LH) CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, Then go to the next
• Turn the ignition switch off. step.
• Measure the resistance between the OCV (LH)
connector terminal B (wiring harness-side) and
PCM terminal 2BK (wiring harness-side).
• Is there continuity?
10 VERIFY TROUBLESHOOTING OF DTC P0020 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using the
M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–24
1890-1U-06H(01-02).fm 25 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0021 [MZI-3.5]
id0102d1950800

DTC P0021 CMP timing over-advanced (LH)

DETECTION • The PCM monitors the variable valve timing position for an over-advanced camshaft timing. The test fails
CONDITION when the camshaft timing exceeds a maximum calibrated value or remains in an advanced position.
• OCV (LH) malfunction
POSSIBLE
• Spool valve in OCV (LH) is stuck in advanced position
CAUSE
• Improper valve timing due to timing chain slippage 01-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY TIMING CHAIN INSTALLATION Yes Go to the next step.
• Stop the engine. No Reinstall the timing chain, then go to Step 5.
• Remove the front cover.
• Is the camshaft timing mark at the correct
point?
(See 01-10-11 TIMING CHAIN REMOVAL/
INSTALLATION [MZI-3.5].)
4 INSPECT OCV (LH) Yes Replace the OCV (LH), then go to the next step.
• Inspect the OCV (LH). (See 01-10-55 OIL CONTROL VALVE (OCV) REMOVAL/
(See 01-10-55 OIL CONTROL VALVE (OCV) INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
5 VERIFY TROUBLESHOOTING OF DTC P0021 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Turn the ignition switch off.
• Start the engine and warm it up completely.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–25
1890-1U-06H(01-02).fm 26 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0022 [MZI-3.5]
id0102d1950900

DTC P0022 CMP timing over-retarded (LH)

DETECTION • The PCM monitors the variable valve timing position for over-retarded camshaft timing. The test fails when
CONDITION the camshaft timing exceeds a maximum calibrated value or remains in a retarded position.
• OCV (LH) malfunction
POSSIBLE • Low engine oil pressure
CAUSE • Spool valve in the OCV (LH) is stuck in retard position
• Improper valve timing due to timing chain slippage

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY ENGINE OIL PRESSURE Yes Inspect the engine oil pressure, then go to Step 6.
• Start the engine. (See 01-11-3 OIL PRESSURE INSPECTION [MZI-3.5].)
• Does the oil pressure warning light illuminate? No Go to the next step.
4 VERIFY TIMING CHAIN INSTALLATION Yes Go to the next step.
• Stop the engine. No Reinstall the timing chain, then go to Step 6.
• Remove the front cover.
• Is the camshaft timing mark at the correct
point?
(See 01-10-11 TIMING CHAIN REMOVAL/
INSTALLATION [MZI-3.5].)
5 INSPECT OCV (LH) Yes Replace the OCV (LH), then go to the next step.
• Inspect the OCV (LH). No Go to the next step.
(See 01-10-55 OIL CONTROL VALVE (OCV)
INSPECTION [MZI-3.5].)
• Is there any malfunction?
6 VERIFY TROUBLESHOOTING OF DTC P0022 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Turn the ignition switch off.
• Start the engine and warm it up completely.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–26
1890-1U-06H(01-02).fm 27 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0040, P0041 [MZI-3.5]
id0102d1880000

DTC P0040 P0040: Front HO2S (LH/RH) signals swapped

DTC P0041 P0041: Rear HO2S (LH/RH) signals swapped
• P0040 indicates that during KOER testing, the front HO2S signal(s) response for a fuel shift to the correct
DETECTION engine bank was not indicated.
CONDITION • P0041 indicates that during KOER testing, the rear HO2S signal(s) response for a fuel shift to the correct
engine bank was not indicated.
01-02
• Crossed HO2S harness connectors.
POSSIBLE
• Crossed wiring at HO2S harness connectors.
CAUSE
• Crossed wiring at PCM harness connector.

STEP INSPECTION ACTION

1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT HO2S WIRING HARNESS Yes Repair if necessary.
CONNECTORS No Go to the next step.
• For P0040, visually inspect the vehicle front
HO2S wiring harness connector (s) for any
indication of crossed wires (Also, stretched or
incorrectly mounted wiring harnesses).
• For P0041, visually inspect the vehicle rear
HO2S wiring harness connector (s) for any
indication of crossed wires (Also, stretched or
incorrectly mounted wiring harnesses).
• Are there crossed connections or wires?
4 VERIFY TROUBLESHOOTING OF DTC P0040, Yes Replace the PCM, then go to the next step.
P0041 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P0053, P0054, P0059, P0060 [MZI-3.5]
id0102d1880100

DTC P0053 P0053: Front HO2S (RH) heater resistance

DTC P0054 P0054: Rear HO2S (RH) heater resistance
DTC P0059 P0059: Front HO2S (LH) heater resistance
DTC P0060 P0060: Rear HO2S (LH) heater resistance
DETECTION • Heater current requirements too low or high in the heated oxygen sensor (HO2S) heater control circuit.
CONDITION
• Open circuit between HO2S terminal C and main relay No.1 terminal E
• Short to ground circuit between HO2S terminal A and body ground
• HO2S circuits are shorted each other
POSSIBLE • DTC P0053: Open circuit between front HO2S (RH) terminal A and PCM terminal 2J
CAUSE • DTC P0054: Open circuit between rear HO2S (RH) terminal A and PCM terminal 2AS
• DTC P0059: Open circuit between front HO2S (LH) terminal A and PCM terminal 2E
• DTC P0060: Open circuit between rear HO2S (LH) terminal A and PCM terminal 2AO
• HO2S heater malfunction

01-02–27
1890-1U-06H(01-02).fm 28 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0053 P0053: Front HO2S (RH) heater resistance
DTC P0054 P0054: Rear HO2S (RH) heater resistance
DTC P0059 P0059: Front HO2S (LH) heater resistance
DTC P0060 P0060: Rear HO2S (LH) heater resistance
MAIN RELAY NO.1
FRONT HO2S (LH) PCM
3 4 5 6
C 7 A 2E FRONT HO2S (LH) HEATER

8
B 2U FRONT HO2S (LH)

FRONT HO2S (RH)

3 4 5 6
C 7 A 2J FRONT HO2S (RH) HEATER

8
B 2Y FRONT HO2S (RH)

D 2AL

REAR HO2S (LH)

3 4 5 6
C 7 A 2AO REAR HO2S (LH) HEATER

8
B 2BC REAR HO2S (LH)

REAR HO2S (RH)

3 4 5 6
C 7 A 2AS REAR HO2S (RH) HEATER

8
B 2BG REAR HO2S (RH)

PCM
FRONT HO2S (LH, RH) REAR HO2S (LH, RH)
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE WIRING HARNESS-SIDE
CONNECTOR CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

C A C A
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
D B D B 2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–28
1890-1U-06H(01-02).fm 29 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT FOR POWER SUPPLY IN WIRING Yes Turn the ignition switch off. Go to the next step.
HARNESS No Repair or replace suspected part, then go to step 9.
• Disconnect the suspect HO2S connector.
• Perform the KOEO self-test.
• Measure the voltage between the suspect
HO2S connector terminal A and C, on the wiring
harness side.
• Is the voltage more than 10 V?
4 INSPECT HO2S HEATER FOR SHORT TO Yes Go to the next step.
GROUND No Repair or replace suspected part, Go to Step 9
• Disconnect the PCM.
• Measure the resistance between HO2S
connector terminal A, the wiring harness side,
and body ground.
• Is the resistance more than 10 kilohms?
5 INSPECT HO2S HEATER FOR SHORT IN Yes Go to the next step.
WIRING HARNESS No Repair or replace suspected part, Go to Step 9
• Measure the resistance between the following
terminals:
— HO2S terminal A (wiring harness-side) and
HO2S terminal C (wiring harness-side)
— HO2S terminal A (wiring harness-side) and
HO2S terminal D (wiring harness-side)
— HO2S terminal A (wiring harness-side) and
HO2S terminal B (wiring harness-side)
• Are the resistances more than 10 kilohms?
6 INSPECT HO2S HEATER CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT IN WIRING HARNESS No Repair or replace suspected part, Go to Step 9.
• For DTC P0053 Measure resistance between
PCM terminal 2J and front HO2S (RH) terminal
A.
• For DTC P0054 Measure resistance between
PCM terminal 2AS and rear HO2S (RH)
terminal A.
• For DTC P0059 Measure resistance between
PCM terminal 2E and front HO2S (LH) terminal
A.
• For DTC P0060 Measure resistance between
PCM terminal 2AO and rear HO2S (LH)
terminal A.
• Is the resistance less than 5.0 ohms?
7 INSPECT INTERNAL RESISTANCE OF HO2S Yes Go to the next step.
HEATER No Replace the HO2S.
• Measure the resistance between the suspect (See 01-40-20 FRONT HEATED OXYGEN SENSOR
HO2S terminal A and C on the component side. (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
• Is the resistance between 3—30 ohms? (See 01-40-23 REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
Go to Step 9.
8 INSPECT HO2S CASE FOR SHORT TO POWER Yes Replace the PCM. Go to the next step.
SUPPLY, HTR, AND SIGNRTN No Replace the HO2S.
• Measure the resistance between the suspect (See 01-40-20 FRONT HEATED OXYGEN SENSOR
HO2S terminal A and D on the component side. (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
• Measure the resistance between the suspect (See 01-40-23 REAR HEATED OXYGEN SENSOR
HO2S terminal A and body ground. (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
• Is the resistance more than 10 kilohms? Go to the next step.

01-02–29
1890-1U-06H(01-02).fm 30 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 VERIFY TROUBLESHOOTING OF MISFIRE DTC Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using the
M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P0068 [MZI-3.5]
id0102d1816800

DTC P0068 MAP/MAF-throttle position correlation

• The PCM monitors a vehicle operation rationality check by comparing sensed throttle position to mass air
DETECTION
flow readings. If during a KOER self-test, the comparison of the TP sensor and MAF sensor readings are
CONDITION
not consistent with the calibrated load values, test fails and a DTC is stored in continuous memory.
• Air leak between MAF sensor and throttle body
POSSIBLE
• TP sensor or MAF sensor malfunction
CAUSE
• TP sensor not seated correctly

01-02–30
1890-1U-06H(01-02).fm 31 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to next step. 01-02
• Is any related Service Bulletins available? No Go to next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC inspection.
STORED DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Verify the related PENDING CODE or stored No Go to next step.
DTCs.
• Are other DTCs present?
4 INSPECT FOR INLET AIR LEAKS Yes Repair as necessary.Go to Step 8.
• Listen for air noise around the MAF sensor and No Go to next step.
throttle body while the engine is running.
• Is a concern present?
5 INSPECT FOR TP2 SIGNAL HIGH VERSUS Yes Replace the malfunctioning part, then go to Step 8.
LOAD WHILE DRIVING THE CVEHICLE No Go to next step.
• Turn the ignition switch to the ON position
(Engine running).
• Access the TP2 and LOAD PIDs using the M-
MDS.
• Is the TP2 PID more than 2.44 V and the LOAD
PID less than 30%?
6 INSPECT FOR TP2 SIGNAL LOW VERSUS Yes Repair or replace the malfunctioning part, then go to Step
LOAD WHILE DRIVING THE CVEHICLE 8.
• Turn the ignition switch to the ON position No Go to next step.
(Engine running).
• Access the PCM and monitor the TP2 and
LOAD PIDs
• Is the TP2 PID less than 0.24 V and the LOAD
PID more than 55%?
7 INSPECT FOR SELF-TEST DTCS Yes Replace the malfunctioning part, then go to the next step.
• Turn the ignition switch to the ON position No Perform the “INTERMITTENT CONCERN
(Engine running). TROUBLESHOOTING”. Then go to the next step.
• Clear DTC from memory using M-MDS.
• Drive the vehicle while exercising the throttle.
• Retrieve the continuous memory DTCs.
• Are any DTCs present?
8 VERIFY TROUBLESHOOTING OF DTC P0068 Yes Replace PCM, then go to next step.
HAS BEEN COMPLETED No Go to next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start engine.
• Perform “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
SOKYU_WM: DTC P01XX

01-02–31
1890-1U-06H(01-02).fm 32 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0102 [MZI-3.5]
id0102d1803200

DTC P0102 MAF circuit low input

DETECTION • The MAF sensor circuit is monitored by the PCM for low air flow (or voltage) input through the CCM. If
CONDITION during KOER the air flow (or voltage) changes below a minimum calibrated limit, the test fails.
• Connector or terminal malfunction
• Open circuit wiring harness between MAF sensor terminal A and main relay No.1 terminal D
• Open circuit wiring harness between MAF sensor terminal C and PCM terminal 1AJ
• Open circuit wiring harness between MAF sensor terminal D and PCM terminal 1AN
POSSIBLE
• Open circuit wiring harness between MAF sensor terminal B and body ground
CAUSE
• Short to ground circuit between MAF sensor terminal D and PCM terminal 1AN
• Intake air leak (near the MAF sensor)
• A closed throttle indication
• MAF sensor malfunction
MAF SENSOR
(MAF/IAT SENSOR) MAIN RELAY NO.1 PCM

3 4
A

3 6 7 5
D 1AN MAF SENSOR (+)

8
3 6 5
C 1AJ MAF SENSOR (-)

3
B

PCM
WIRING HARNESS-SIDE CONNECTOR
MAF/IAT SENSOR
MAIN RELAY NO.1 WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
A E 1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

C
F E D C B A 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
D 1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–32
1890-1U-06H(01-02).fm 33 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT MAF SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 10.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction? 01-02
4 INSPECT POWER SUPPLY CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between MAF sensor
terminal A and body ground.
• Is the voltage B+?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT MAF SENSOR SIGNAL CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Remove PCM with PCM connector connected.
• Inspect for continuity between the following
circuits:
— MAF sensor terminal C (wiring harness-
side) and PCM terminal 1AJ (wiring
harness-side)
— MAF sensor terminal D (wiring harness-
side) and PCM terminal 1AN (wiring
harness-side)
• Are there continuity?
7 INSPECT MAF SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to the Step 10.
SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor and PCM
connector.
• Inspect continuity between following circuits:
— MAF sensor connector terminal D and body
ground
• Are there continuity?
8 INSPECT MAF SENSOR GROUND CIRCUIT Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Inspect continuity between MAF sensor
terminal B and body ground.
• Are there continuity?
9 INSPECT THE MAF SENSOR Yes Replace the MAF/IAT sensor, then go to the next step.
• Inspect the MAF sensor (See 01-40-9 MASS AIR FLOW (MAF)/INTAKE AIR
(See 01-40-9 MASS AIR FLOW (MAF) TEMPERATURE (IAT) SENSOR REMOVAL/
SENSOR INSPECTION [MZI-3.5].) INSTALLATION [MZI-3.5].)
• Are there any malfunction? No Go to the next step.
10 VERIFY TROUBLESHOOTING OF DTC P0102 Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start engine and warm it up completely.
• Is same DTC present?

01-02–33
1890-1U-06H(01-02).fm 34 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P0103 [MZI-3.5]
id0102d1803300

DTC P0103 MAF circuit high input

DETECTION • The MAF sensor circuit is monitored by the PCM for high air flow (or voltage) input through the CCM. If
CONDITION during KOEO, or KOER, the air flow (or voltage) changes above a maximum calibrated limit, the test fails.
• Short to power supply in wiring harness between MAF sensor terminal D and PCM terminal 1AN
POSSIBLE
• MAF sensor malfunction
CAUSE
• Connector or terminal malfunction
MAF SENSOR
(MAF/IAT SENSOR) MAIN RELAY NO.1 PCM

3
A

3 4 5
D 1AN MAF SENSOR (+)

6
3 5
C 1AJ MAF SENSOR (-)

3
B

PCM
WIRING HARNESS-SIDE CONNECTOR
MAF/IAT SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

F E D C B A 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

01-02–34
1890-1U-06H(01-02).fm 35 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT MAF SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 7.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT MAF SIGNAL CIRCUIT FOR SHORT No Repair or replace suspected part, then go to Step 7.
TO POWER SUPPLY Yes Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between MAF sensor terminal
D (wiring harness-side) and body ground.
• Is voltage B+?
5 INSPECT PCM CONNECTOR FOR POOR No Repair or replace suspected part, then go to Step 7.
CONNECTION Yes Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT THE MAF SENSOR Yes Replace the MAF/IAT sensor (See 01-40-9 MASS AIR
• Inspect the MAF sensor. FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR
(See 01-40-9 MASS AIR FLOW (MAF) REMOVAL/INSTALLATION [MZI-3.5].), then go to Step 7.
SENSOR INSPECTION [MZI-3.5].) No Go to the next step.
• Is there malfunction?
7 VERIFY TROUBLESHOOTING OF DTC P0103 Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start engine and warm it up completely.
• Is same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
WM: DTC P01XX

01-02–35
1890-1U-06H(01-02).fm 36 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0104 [MZI-3.5]
id0102d1816900

DTC P0104 MAF circuit intermittent/erratic

DETECTION • A concern exists in the MAF sensor circuit, or the air tube containing the sensor, causing an incorrect air
CONDITION flow reading.
• Air leaks in the tube from the MAF to the throttle body
• Open circuit wiring harness between MAF sensor terminal C and PCM terminal 1AJ
• Open circuit wiring harness between MAF sensor terminal D and PCM terminal 1AN
POSSIBLE • Short to power supply in wiring harness between MAF sensor terminal C and PCM terminal 1AJ
CAUSE • Short to power supply in wiring harness between MAF sensor terminal D and PCM terminal 1AN
• Short to ground circuit between MAF sensor terminal C and PCM terminal 1AJ
• Short to ground circuit between MAF sensor terminal D and PCM terminal 1AN
• Connector or terminal malfunction
MAF SENSOR
(MAF/IAT SENSOR) MAIN RELAY NO.1 PCM

5
A

5 6 7 9 8
D 1AN MAF SENSOR (+)

5 6 7 9 8
C 1AJ MAF SENSOR (-)

5
B

PCM
WIRING HARNESS-SIDE CONNECTOR
MAF/IAT SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

F E D C B A 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to next step.
• Is any related Service Bulletins available? No Go to next step.

01-02–36
1890-1U-06H(01-02).fm 37 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC inspection.
STORED DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Verify the related PENDING CODE or stored No Go to next step.
DTCs.
• Are other DTCs present?
4 INSPECT AIR SUCTIONING BETWEEN MAF Yes Repair or replace the malfunctioning part, then go to Step
SENSOR AND TP SENSOR 10. 01-02
• Inspect for major leaks, cracks and openings No Go to next step.
between MAF sensor and throttle body.
• Are there any malfunction?
5 INSPECT MAF SENSOR CONNECTOR FOR Yes Repair or replace the malfunctioning part, then go to Step
POOR CONNECTION 10.
• Turn the ignition switch off. No Go to next step.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT MAF SIGNAL CIRCUIT FOR SHORT Yes Repair or replace the malfunctioning part, then go to Step
TO POWER SUPPLY 10.
• Turn the ignition switch to the ON position No Go to next step.
(Engine off).
• Measure voltage between the following
terminals:
— MAF sensor terminal C (wiring harness-
side) and body ground
— MAF sensor terminal D (wiring harness-
side) and body ground
• Are there voltage B+?
7 INSPECT MAF SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace the malfunctioning part, then go to Step
SHORT TO GROUND 10.
• Turn the ignition switch off. No Go to next step.
• Disconnect the MAF/IAT sensor and PCM
connector.
• Inspect for continuity between the following
circuits:
— MAF sensor terminal C (wiring harness-
side) and body ground
— MAF sensor terminal D (wiring harness-
side) and body ground
• Are there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the malfunctioning part, then go to Step
CONNECTION 10.
• Turn the ignition switch off. No Go to next step.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
9 INSPECT MAF SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Disconnect the MAF/IAT sensor connector.
• Inspect for continuity between the following
terminals:
— MAF sensor terminal C and PCM terminal
1AJ
— MAF sensor terminal D and PCM terminal
1AN
• Are there continuity?

01-02–37
1890-1U-06H(01-02).fm 38 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
10 VERIFY TROUBLESHOOTING OF DTC P0104 Yes Replace the PCM, then go to next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to next step.
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P0111 [MZI-3.5]
SOKYU_WM: DTC P01XX

id0102d1803600

DTC P0111
IAT sensor circuit range/performance
• Indicates the IAT rationality test has failed. This DTC indicates that the IAT value is higher than a calibrated
value and could prevent 1 or more on-board diagnostic (OBD) monitors from completing.The PCM runs this
DETECTION
logic after an engine off and a calibrated soak period (typically 6 hours) This soak period allows IAT and
CONDITION
CHT to stabilize and not differ by more than a calibrated value. DTC P0111 is set when: the IAT at engine
start exceeds the CHT by more than a calibrated value, typically 17 °C {30 °F}.
POSSIBLE
• IAT sensor malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT IAT SENSOR Yes Go to the next step.
• Inspect IAT sensor. No Replace MAF/IAT sensor, then go to the next step.
(See 01-13-4 INTAKE-AIR SYSTEM (See 01-40-9 MASS AIR FLOW (MAF)/INTAKE AIR
REMOVAL/INSTALLATION [MZI-3.5].) TEMPERATURE (IAT) SENSOR REMOVAL/
• Is IAT sensor normal? INSTALLATION [MZI-3.5].)
4 VERIFY TROUBLESHOOTING OF DTC P0111 Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M–MDS.
• Start engine and run engine under FREEZE
FRAME DATA condition.
• Is PENDING CODE for this DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–38
1890-1U-06H(01-02).fm 39 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0112 [MZI-3.5]
id0102d1803700

DTC P0112 IAT sensor circuit low input

DETECTION • Indicates that the sensor signal is less than the self-test minimum. The IAT sensor minimum is 0.2 V or 121
CONDITION °C {250 °F}.
• Short to ground circuit between MAF/IAT sensor terminal F and PCM terminal 1AF
POSSIBLE
• IAT sensor malfunction
CAUSE
• Connector or terminal malfunction 01-02
IAT SENSOR
(MAF/IAT SENSOR) PCM

3 6 5
F 1AF

3 6
E 1AL

PCM
WIRING HARNESS-SIDE CONNECTOR
MAF/IAT SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

F E D C B A 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT IAT SENSOR TERMINAL Yes Repair or replace suspected part, then go to Step 6.
• Turn the ignition switch off. No Go to the next step.
• Disconnect MAF/IAT sensor connector.
• Inspect for bent terminal of MAF/IAT sensor
terminals E and F (part-side).
• Is there any malfunction?
4 CLASSIFY IAT SENSOR MALFUNCTION OR Yes Replace MAF/IAT sensor or harness, then go to Step 6.
HARNESS MALFUNCTION No Go to the next step.
• Connect M–MDS to DLC-2.
• Access IAT PID.
• Verify IAT value when disconnecting MAF/IAT
sensor connector.
• Does IAT value change?

01-02–39
1890-1U-06H(01-02).fm 40 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT IAT SIGNAL CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to the next step.
GROUND No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect continuity between MAF/IAT sensor
terminal F (wiring harness-side) and body
ground.
• Is there continuity?
6 VERIFY TROUBLESHOOTING OF DTC P0112 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start engine and warm it up completely.
• Is same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–40
1890-1U-06H(01-02).fm 41 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0113 [MZI-3.5]
id0102d1803800

DTC P0113 IAT sensor circuit high input

DETECTION • Indicates the sensor signal is more than the self-test maximum. The IAT sensor maximum is 4.6 V or –50
CONDITION °C {–58 °F}.
• Open circuit between MAF/IAT sensor terminal E and PCM terminal 1AL
• Open circuit between MAF/IAT sensor terminal F and PCM terminal 1AF
POSSIBLE
• Short to power supply between MAF/IAT sensor terminal F and PCM terminal 1AF 01-02
CAUSE
• IAT sensor malfunction
• Connector or terminal malfunction
IAT SENSOR
(MAF/IAT SENSOR) PCM

3 5 7 6
F 1AF

3 5 8 6
E 1AL

PCM
WIRING HARNESS-SIDE CONNECTOR
MAF/IAT SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

F E D C B A 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT IAT SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 9.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–41
1890-1U-06H(01-02).fm 42 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 CLASSIFY IAT SENSOR MALFUNCTION OR Yes Inspect the IAT sensor.
HARNESS MALFUNCTION (See 01-40-11 INTAKE AIR TEMPERATURE (IAT)
• Disconnect the MAF/IAT sensor connector. SENSOR INSPECTION [MZI-3.5].)
• Turn the ignition switch to the ON position Replace if necessary, then go to Step 9.
(Engine off). No Go to the next step.
• Measure voltage between MAF/IAT sensor
terminal F (wiring harness-side) and body
ground.
• Is voltage 4.5—5.5 V?
5 INSPECT IAT SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 9.
SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between MAF/IAT sensor
terminal F (wiring harness-side) and body
ground.
• Is voltage B+?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
7 INSPECT IAT SENSOR SIGNAL CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Inspect continuity between MAF/IAT sensor
terminal F (wiring harness-side) and PCM
terminal 1AF (wiring harness-side).
• Is there continuity?
8 INSPECT IAT SENSOR GROUND CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to the next step.
• Inspect continuity between MAF/IAT sensor
terminal E (wiring harness-side) and PCM
terminal 1AL (wiring harness-side).
• Is there continuity?
9 VERIFY TROUBLESHOOTING OF DTC P0113 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start engine and warm it up completely.
• Is same DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P01XX

01-02–42
1890-1U-06H(01-02).fm 43 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0114 [MZI-3.5]
id0102d1817000

DTC P0114 IAT sensor Intermittent/erratic

DETECTION • Indicates the sensor signal was intermittent during the CCM.
CONDITION
• IAT sensor malfunction
POSSIBLE
• Harness malfunction
CAUSE
• Connector or terminal malfunction 01-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT CONNECTOR FOR POOR Yes Go to the next step.
CONNECTION No Repair or replace suspected part, then go to Step 6.
• Turn the ignition switch off.
• Disconnect PCM connector and IAT sensor
connectors.
• Inspect for poor connection (such as damaged,
pulled-out pins, and corrosion).
• Is there any malfunction?
4 INTERMITTENT INSPECTION Yes Inspect the IAT sensor.
• Turn the ignition switch to the ON position (See 01-40-11 INTAKE AIR TEMPERATURE (IAT)
(Engine off). SENSOR INSPECTION [MZI-3.5].)
• Access the PCM and monitor the IAT PID. Replace if necessary, then go to Step 6.
• While observing the PID, perform the following: No Go to the next step.
— Tap on the sensor to simulate road shock
— Wiggle the sensor connector
• Is there a large change in the voltage reading?
5 INSPECT ELECTRONIC ENGINE CONTROL Yes Repair if necessary, then go to Step 6.
WIRING HARNESS No Go to the next step.
• Access the PCM and monitor the IAT PID.
• While observing the PID, wiggle, shake, and
bend small sections of the wiring harness while
working from the sensor to the PCM.
• Is there a large change in the voltage reading?
6 VERIFY TROUBLESHOOTING OF DTC P0114 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using the
M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–43
1890-1U-06H(01-02).fm 44 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0116 [MZI-3.5]
id0102d1803900

DTC P0116
CHT sensor circuit range/performance
• Indicates the engine coolant temperature logic test has failed. This DTC indicates that the CHT value is
higher than the calibrated value and could prevent 1 or more OBD monitors from completing.
The PCM runs this logic after an engine off and a calibrated soak period (typically 6 hours).
This soak period allows the IAT and the CHT to stabilize and not differ by more than a calibrated value.
DETECTION DTC P0116 is set when all of the following conditions are met:
CONDITION — The CHT at engine start exceeds the IAT at engine start by more than a calibrated value, typically 17 °C
{30 °F}.
— The CHT exceeds a calibrated value, typically 107 °C {225 °F}.
— The fuel system, heated oxygen and misfire monitors have not completed.
— The calibrated time to set DTC P0116 has expired.
POSSIBLE • Cooling system malfunction
CAUSE • CHT sensor malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line If the vehicle is not repaired, go to next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC inspection.
STORED DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Verify the related PENDING CODE or stored No Go to the next step.
DTCs.
• Are other DTCs present?
4 INSPECT CHT SENSOR Yes Replace the CHT sensor, then go to the next step.
• Inspect the CHT sensor. No Go to the next step.
(See 01-40-28 CYLINDER HEAD
TEMPERATURE (CHT) SENSOR
INSPECTION [MZI-3.5].)
• Are there any malfunction?
5 VERIFY TROUBLESHOOTING OF DTC P0116 Yes Replace the PCM, then go to next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the "KOEO/KOER self-test" (See 01-
02-8 KOEO/KOER SELF TEST [MZI-3.5].)
• Is same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
SOKYU_WM: DTC P01XX

01-02–44
1890-1U-06H(01-02).fm 45 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0119 [MZI-3.5]
id0102d1817100

DTC P0119 CHT sensor circuit intermittent/erratic

DETECTION
• Indicates the ECT circuit became intermittently open or shorted while the engine was running.
CONDITION
• Harness malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Low engine coolant 01-02
• CHT sensor malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.
3 INSPECT CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector and CHT sensor
connectors.
• Inspect for poor connection (such as damaged,
pulled-out pins, and corrosion).
• Is there any malfunction?
4 INTERMITTENT INSPECTION Yes Inspect the CHT sensor.
• Turn the ignition switch to the ON position (See 01-40-28 CYLINDER HEAD TEMPERATURE (CHT)
(Engine off). SENSOR INSPECTION [MZI-3.5].)
• Access the PCM and monitor the CHT PID. Replace if necessary, then go to Step 7.
• While observing the PID, perform the following: No Go to the next step.
— Tap on the sensor to simulate road shock
— Wiggle the sensor connector
• Is there a large change in the voltage reading?
5 INSPECT ELECTRONIC ENGINE CONTROL Yes Repair if necessary, then go to Step 7.
(EEC) WIRING HARNESS No Go to the next step.
• Access the PCM and monitor the CHT PID.
• While observing the PID, wiggle, shake, and
bend small sections of the wiring harness while
working from the sensor to the PCM.
• Is there a large change in the voltage reading?
6 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect the PCM connector. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY TROUBLESHOOTING OF DTC P0119 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

01-02–45
1890-1U-06H(01-02).fm 46 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

End Of Sie

DTC P0122 [MZI-3.5]

id0102d1804200

DTC P0122 TP sensor No.1 circuit low input

DETECTION
• The TP sensor No.1 circuit was flagged as a concern by the PCM indicating a low voltage or open circuit.
CONDITION
• TP sensor No.1 malfunction
• Connector or terminal malfunction
POSSIBLE
• Open circuit between throttle body terminal F and PCM terminal 2Z
CAUSE
• Short to ground circuit between throttle body terminal F and PCM terminal 2Z
• Open circuit between throttle body terminal E and PCM terminal 2AH
TP SENSOR NO.1 (THROTTLE BODY) PCM

8
3 5
D 2D

3 4 6 5
F 2Z

3 7 5
E 2AH

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–46
1890-1U-06H(01-02).fm 47 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT TP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 9.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the throttle body connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT TP SENSOR CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to Step 9.
GROUND No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect for continuity between TP sensor
terminal F (wiring harness-side) and body
ground
• Is there continuity?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT TP SIGNAL CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Inspect for continuity between throttle body
connector terminal F (wiring harness-side) and
PCM terminal 2Z (wiring harness-side).
• Is there continuity?
7 INSPECT TP GROUND CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Turn the ignition switch off.
• Verify the continuity between TP sensor
terminal E (wiring harness-side) and PCM
terminal 2AH (wiring harness-side).
• Is the continuity?
8 INSPECT TP SENSOR NO.1 Yes Replace the throttle body, then go to the next step.
• Inspect the TP sensor No.1. No Go to the next step.
(See 01-40-12 THROTTLE POSITION (TP)
SENSOR INSPECTION [MZI-3.5].)
• Is there any malfunction?
9 VERIFY TROUBLESHOOTING OF DTC P0122 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

01-02–47
1890-1U-06H(01-02).fm 48 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

End Of Sie

DTC P0123 [MZI-3.5]

id0102d1804300

DTC P0123 TP sensor No.1 circuit high input

DETECTION
• The TP sensor No.1 circuit was flagged as a concern by the PCM indicating a high voltage.
CONDITION
• TP sensor No.1 malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Short to constant voltage supply circuit between throttle body terminal F and PCM terminal 2Z
• TP sensor signal circuits are shorted each other
TP SENSOR NO.1 (THROTTLE BODY) PCM

7
3 6 4
D 2D

3 6 4
F 2Z

3 4
E 2AH

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–48
1890-1U-06H(01-02).fm 49 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT TP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 8.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the throttle body connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
5 INSPECT TP SIGNAL CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to Step 8.
POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between Throttle body
connector terminal F (wiring harness-side) and
body ground.
• Is the voltage B+?
6 INSPECT TP SENSOR SIGNAL CIRCUITS FOR Yes Go to the next step.
SHORT EACH OTHER No Repair or replace suspected part, then go to Step 8.
• Disconnect the TP sensor and PCM connector.
• Measure resistance between Throttle body
connector terminal D and F
• Is the resistance more than 10 kilohms?
7 INSPECT TP SENSOR NO.1 Yes Replace the throttle body, then go to the next step.
• Inspect the TP sensor No.1. No Go to the next step.
(See 01-40-12 THROTTLE POSITION (TP)
SENSOR INSPECTION [MZI-3.5].)
• Are there any malfunction?
8 VERIFY TROUBLESHOOTING OF DTC P0123 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P01XX

01-02–49
1890-1U-06H(01-02).fm 50 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0128 [MZI-3.5]
id0102d1817300

DTC P0128 Coolant thermostat (coolant temp below thermostat regulating temperature)
DETECTION • P0128 Indicates that the thermostat monitor has not achieved the required engine operating temperature
CONDITION within a specified amount of time after starting the engine.
• Insufficient warm up time
POSSIBLE • Low engine coolant level
CAUSE • Leaking or stuck open thermostat
• Inoperative cylinder head temperature (CHT) sensor

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT ENGINE COOLANT LEVEL Yes Go to the next step.
No Inspect for a loss of engine coolant. Repair if necessary.
Warning (See 01-12-6 ENGINE COOLANT LEAKAGE
• Never remove the cooling system cap or INSPECTION [MZI-3.5].)
loosen the radiator drain plug while the Go to Step 5.
engine is running, or when the engine
and radiator are hot. Scalding engine
coolant and steam may shoot out and
cause serious injury. It may also damage
the engine and cooling system.
• Turn off the engine and wait until it is
cool. Even then, be very careful when
removing the cap. Wrap a thick cloth
around it and slowly turn it
counterclockwise to the first stop. Step
back while the pressure escapes.
• When you're sure all the pressure is
gone, press down on the cap using the
cloth, turn it, and remove it.

• Is the engine coolant fill level correct?

4 INSPECT SENSOR OPERATION Yes The test is complete. Go to the next step.
• Run the engine until the engine temperature No Inspect the thermostat operation. Repair if necessary.
stabilizes. (See 01-12-11 THERMOSTAT INSPECTION [MZI-3.5].)
• Verify that the radiator hoses are hot and the
cooling system is pressurized.
• Access the PCM and monitor the CHT PID.
• Is the temperature more than 77 °C {170.6 °F}?
5 VERIFY TROUBLESHOOTING OF DTC P0128 Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–50
1890-1U-06H(01-02).fm 51 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0132, P0138, P0152, P0158 [MZI-3.5]
id0102d1880200

DTC P0132 P0132: Front HO2S (RH) circuit high voltage

DTC P0138 P0138: Rear HO2S (RH) circuit high voltage
DTC P0152 P0152: Front HO2S (LH) circuit high voltage
DTC P0158 P0158: Rear HO2S (LH) circuit high voltage
DETECTION • The HO2S signals are monitored for an over voltage condition.
CONDITION • The code is set when the HO2S signal voltage is 1.5 V or more.
01-02
POSSIBLE
• Short to power supply in the wiring harness or HO2S
CAUSE
FRONT HO2S (LH) PCM
3 5 7 8
B 2U FRONT HO2S (LH)

3
D

FRONT HO2S (RH)

3 5 7 8
B 2Y FRONT HO2S (RH)

3 8
D 2AL

REAR HO2S (LH)

3 5 7 8
B 2BC REAR HO2S (LH)

3
D

REAR HO2S (RH)

3 5 7 8
B 2BG REAR HO2S (RH)

3
D

PCM
FRONT HO2S (LH, RH) REAR HO2S (LH, RH)
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE WIRING HARNESS-SIDE
CONNECTOR CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

C A C A
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
D B D B 2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–51
1890-1U-06H(01-02).fm 52 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VISUALLY INSPECT HO2S WIRING HARNESS Yes Repair if necessary. Go to Step 9.
No Go to the next step.
Note
• Disconnect the HO2S wiring harness
connector.

• Turn the ignition switch off.

• Disconnect the HO2S connector.
• Visually inspect the HO2S wiring harness.
— Check the connector (both halves) for
contamination
— Make sure the connector pins are fully
seated
• Is a concern present?
4 INSPECT WHETHER HO2S SIGNAL LEVEL IS Yes Go to the next step.
TOO HIGH No Go to Step 6.
• Connect the HO2S connector.
• Perform the KOER self-test.
• Access the PCM and monitor the HO2S signal
PID.
• Is the voltage less than 1.1 V?
5 PERFORM THOROUGH WIGGLE TEST ON Yes Repair if necessary. Go to Step 9.
HO2S WIRING HARNESS No Perform the “INTERMITTENT CONCERN
• Turn the ignition switch off. TROUBLESHOOTING”. Then go to the next step.
• Perform the KOEO self-test.
• Access the PCM and monitor the HO2S signal
PID.
• Perform a thorough wiggle test on the HO2S
wiring harness.
• Does the voltage change during the wiggle
test?
6 INSPECT HO2S SIGNAL FOR SHORT TO Yes Replace the HO2S.
POWER SUPPLY INSIDE SENSOR (See 01-40-20 FRONT HEATED OXYGEN SENSOR
• Turn the ignition switch off. (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
• Disconnect the HO2S connector. (See 01-40-23 REAR HEATED OXYGEN SENSOR (HO2S)
• Perform the KOER self-test. REMOVAL/INSTALLATION [MZI-3.5].)
• Access the PCM and monitor the HO2S signal Then go to Step 9.
PID. No Go to the next step.
• Is the voltage less than 1.1 V?
7 INSPECT HO2S CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, Then go to the next step.
POWER SUPPLY IN WIRING HARNESS No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Perform the KOEO self-test.
• Measure the voltage between HO2S terminal B
and body ground.
• Is any voltage present?
8 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No Repair if necessary. Then go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.

01-02–52
1890-1U-06H(01-02).fm 53 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 VERIFY TROUBLESHOOTING OF MISFIRE DTC Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using 01-02
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P0133, P0139, P0153, P0159 [MZI-3.5]
SOKYU_WM: DTC P01XX

id0102d1877100

DTC P0133 P0133: Front HO2S (RH) circuit slow response

DTC P0139 P0139: Rear HO2S (RH) circuit slow response
DTC P0153 P0153: Front HO2S (LH) circuit slow response
DTC P0159 P0159: Rear HO2S (LH) circuit slow response
DETECTION • The HO2S monitor checks the HO2S frequency and amplitude.
CONDITION • The test fails if the frequency and amplitude fall below a calibrated limit during testing.
• Contaminated HO2S
• Exhaust leaks
• Open circuit in wiring harness between PCM terminal 2Y (wiring harness-side) and front HO2S (RH)
terminal B (wiring harness-side)
• Open circuit in wiring harness between PCM terminal 2BG (wiring harness-side) and rear HO2S (RH)
terminal B (wiring harness-side)
• Open circuit in wiring harness between PCM terminal 2U (wiring harness-side) and front HO2S (LH)
terminal B (wiring harness-side)
• Open circuit in wiring harness between PCM terminal 2BC (wiring harness-side) and rear HO2S (LH)
terminal B (wiring harness-side)
• Open circuit in wiring harness between PCM terminal 2AL (wiring harness-side) and HO2S terminal D
(wiring harness-side)
• Short to ground in wiring harness between PCM terminal 1BJ (wiring harness-side) and PCM terminal 2Y
(wiring harness-side)
• Short to ground in wiring harness between PCM terminal 1BJ (wiring harness-side) and PCM terminal 2BG
(wiring harness-side)
• Short to ground in wiring harness between PCM terminal 1BJ (wiring harness-side) and PCM terminal 2U
POSSIBLE (wiring harness-side)
CAUSE • Short to ground in wiring harness between PCM terminal 1BJ (wiring harness-side) and PCM terminal 2BC
(wiring harness-side)
• Short to ground in wiring harness between HO2S terminal A (wiring harness-side) and battery negative
terminal
• Short to ground in wiring harness between HO2S terminal A (wiring harness-side) and HO2S terminal C
(wiring harness-side)
• Short to ground in wiring harness between HO2S terminal A (wiring harness-side) and HO2S terminal D
(wiring harness-side)
• Short to ground in wiring harness between HO2S terminal A (wiring harness-side) and HO2S terminal B
(wiring harness-side)
• Short to ground in wiring harness between PCM terminal 2J and front HO2S (RH) terminal A
• Short to ground in wiring harness between PCM terminal 2AS and front HO2S (LH) terminal A
• Short to ground in wiring harness between PCM terminal 2E and rear HO2S (RH) terminal A
• Short to ground in wiring harness between PCM terminal 2AO and rear HO2S (LH) terminal A
• Incorrect fueling
• MAF sensor malfunction
• Deteriorating HO2S
• Inlet air leaks

01-02–53
1890-1U-06H(01-02).fm 54 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0133 P0133: Front HO2S (RH) circuit slow response
DTC P0139 P0139: Rear HO2S (RH) circuit slow response
DTC P0153 P0153: Front HO2S (LH) circuit slow response
DTC P0159 P0159: Rear HO2S (LH) circuit slow response
MAIN RELAY NO.1
FRONT HO2S (LH) PCM
5 9 11 9 12 13 16
C 14 A 2E FRONT HO2S (LH) HEATER

15 9 6 7 10 16
B 2U FRONT HO2S (LH)

9 6 10
D

FRONT HO2S (RH)

5 9 11 9 12 13 16
C 14 A 2J FRONT HO2S (RH) HEATER

15 9 6 7 10 16
B 2Y FRONT HO2S (RH)

9 16
D 2AL

REAR HO2S (LH)

5 9 11 9 12 13 16
C 14 A 2AO REAR HO2S (LH) HEATER

15 9 6 7 10 16
B 2BC REAR HO2S (LH)

9 6
D
10
REAR HO2S (RH)
5 9 11 9 12 13 16
C 14 A 2AS REAR HO2S (RH) HEATER

15 9 6 7 10 16
B 2BG REAR HO2S (RH)

9 6
D
10

PCM
FRONT HO2S (LH, RH) REAR HO2S (LH, RH)
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE WIRING HARNESS-SIDE
CONNECTOR CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

C A C A
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
D B D B 2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–54
1890-1U-06H(01-02).fm 55 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 PERFORM KOER SELF-TEST Yes Go to the appropriate DTC troubleshooting.
• Verify that the engine is at normal operating (See 01-02-12 DTC TABLE [MZI-3.5].)
temperature. No Go to the next step.
• Perform the KOER self-test.
• Are DTCs P0040, P0041 or P1127 present?
4 INSPECT FOR UNMETERED AIR LEAKS Yes Repair the source of the air leak. Then go to Step 17.
No Go to the next step.
Note
• Fuel calculations can be affected by
unmetered air leaks.

• Carefully inspect the following areas for

potential air leaks:
— Hoses connecting to the MAF sensor
assembly
— Hoses connecting to the throttle body
— Intake manifold gasket leaks
— PCV system
— The vacuum lines are disconnected
— Improperly seated engine oil dipstick, tube
or oil filler cap
— Exhaust leaks at flanges and gaskets
• Are any air leaks present?
5 INSPECT HO2S CIRCUIT CONTINUITY Yes Replace the HO2S.
• Disconnect the HO2S connector. (See 01-40-20 FRONT HEATED OXYGEN SENSOR
• Check the connector (both halves) for any (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
water contamination. (See 01-40-23 REAR HEATED OXYGEN SENSOR (HO2S)
• Connect a 5 A fused jumper wire between the REMOVAL/INSTALLATION [MZI-3.5].)
HO2S connector B and C on the wiring Then go to Step 17.
harness side. No Go to the next step.
• Perform the KOER self-test.
• Access the PCM and monitor the HO2S signal
PID.
• Is the voltage more than 1 V?

01-02–55
1890-1U-06H(01-02).fm 56 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
6 INSPECT HO2S CIRCUIT (S) FOR OPEN Yes Go to the next step.
CIRCUIT IN WIRING HARNESS No Repair or replace suspected part, Then go to Step 17.
• Turn the ignition switch off.
• Remove the jumper wire (s).
• Visually inspect the HO2S wiring harness for
exposed wiring, water contamination,
corrosion, and proper assembly.
• Disconnect the PCM connector.
• Measure the resistance between the following
terminals:
— PCM terminal 2Y (wiring harness-side) and
front HO2S (RH) terminal B (wiring harness-
side)
— PCM terminal 2BG (wiring harness-side)
and rear HO2S (RH) terminal B (wiring
harness-side)
— PCM terminal 2U (wiring harness-side) and
front HO2S (LH) terminal B (wiring harness-
side)
— PCM terminal 2BC (wiring harness-side)
and rear HO2S (LH) terminal B (wiring
harness-side)
— PCM terminal 2AL (wiring harness-side) and
HO2S terminal D (wiring harness-side)
• Are the resistances less than 5 ohms?
7 INSPECT HO2S CIRCUIT FOR SHORT TO Yes Go to the next step.
POWER SUPPLY No Go to Step 11.
• Measure the resistance between the following
terminals:
— PCM terminal 1BJ (wiring harness-side) and
PCM terminal 2Y (wiring harness-side)
— PCM terminal 1BJ (wiring harness-side) and
PCM terminal 2BG (wiring harness-side)
— PCM terminal 1BJ (wiring harness-side) and
PCM terminal 2U (wiring harness-side)
— PCM terminal 1BJ (wiring harness-side) and
PCM terminal 2BC (wiring harness-side)
• Is the resistance more than 10 kilohms?
8 INSPECT FOR SOURCE OF POTENTIAL HO2S Yes Repair the source of the contamination. Change the engine
CONTAMINATION oil and oil filter. Then go to Step 17.
• Investigate the following items as potential No Go to the next step.
sources of HO2S contamination:
— Use of unapproved silicon sealers
— Fuel contaminated by silicon additives
— Excessive oil consumption
— Glycol leaking internally in the engine
— Lead-contaminated fuel
— Short drive cycles in cold weather
— Use of unapproved cleaning agents
• Is a concern present?
9 VISUALLY INSPECT HO2S WIRING HARNESS Yes Repair if necessary. Then go to the next step.
• Connect the PCM connector. No Go to the next step.
• Visually inspect the HO2S wiring harness for
exposed wiring water contamination, corrosion,
and proper assembly.
• Is a concern present?

01-02–56
1890-1U-06H(01-02).fm 57 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
10 INSPECT HO2S AND SIGRTN CIRCUITS FOR Yes Go to the next step.
OPEN CIRCUIT IN WIRING HARNESS No Repair or replace suspected part, Then go to Step 17.

Note
• Verify the wiring harness terminals are in the
proper location.
01-02
• Measure the resistance between the following
terminals:
— PCM terminal 2Y (wiring harness-side) and
front HO2S (RH) terminal B (wiring harness-
side)
— PCM terminal 2BG (wiring harness-side)
and rear HO2S (RH) terminal B (wiring
harness-side)
— PCM terminal 2U (wiring harness-side) and
front HO2S (LH) terminal B (wiring harness-
side)
— PCM terminal 2BC (wiring harness-side)
and rear HO2S (LH) terminal B (wiring
harness-side)
— PCM terminal 2AL (wiring harness-side) and
HO2S terminal D (wiring harness-side)
• Are the resistances less than 5 ohms?
11 INSPECT HO2S CONTROL CIRCUIT IN WIRING Yes Go to the next step.
HARNESS No Repair or replace suspected part, Then go to the next step.
• Turn the ignition switch off.
• Disconnect the HO2S connector.
• Perform the KOEO self-test.
• Measure the voltage between: HO2S
connector terminal C and D on the wiring
harness side.
• Is the voltage more than 10 V?
12 INSPECT HO2S HEATER FOR SHORT IN Yes Go to the next step.
WIRING HARNESS No Repair or replace suspected part, Then go to Step 17.
• Turn the ignition switch off.
• Disconnect the HO2S connector.
• Disconnect the PCM connector.
• Measure the resistance between the following
terminals:
— HO2S terminal A (wiring harness-side) and
battery negative terminal
— HO2S terminal A (wiring harness-side) and
HO2S terminal C (wiring harness-side)
— HO2S terminal A (wiring harness-side) and
HO2S terminal D (wiring harness-side)
— HO2S terminal A (wiring harness-side) and
HO2S terminal B (wiring harness-side)
• Are the resistances more than 10kilohms?
13 INSPECT HO2S HEATER CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT IN WIRING HARNESS No Repair or replace suspected part, Then go to the next step.
• Measure the resistance:
— For DTC P0133 measure resistance
between PCM terminal 2J and front HO2S
(RH) terminal A
— For DTC P0153 measure resistance
between PCM terminal 2AS and rear HO2S
(RH) terminal A
— For DTC P0139 measure resistance
between PCM terminal 2E and front HO2S
(LH) terminal A
— For DTC P0159 measure resistance
between PCM terminal 2AO and rear HO2S
(LH) terminal A
• Is the resistance less than 5 ohms?

01-02–57
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
14 INSPECT INTERNAL RESISTANCE OF HO2S Yes Go to the next step.
HEATER No Install a new HO2S. Then go to Step 17.
• Measure the resistance between the suspect
HO2S terminal A and C at component side.
• Is the resistance between 3—30 ohms?
15 INSPECT HO2S HEATER CIRCUIT FOR Yes Go to the next step.
INTERNAL SHORT TO SIGRTN OR GROUND No Replace the HO2S.
• Measure the resistance between: (See 01-40-20 FRONT HEATED OXYGEN SENSOR
— HO2S terminal A and D at component side (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
— HO2S terminal A at component side and (See 01-40-23 REAR HEATED OXYGEN SENSOR (HO2S)
battery negative terminal REMOVAL/INSTALLATION [MZI-3.5].)
• Is the resistance more than 10 kilohms? Then go to Step 17.
16 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
17 VERIFY TROUBLESHOOTING OF MISFIRE DTC Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
18 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P0135, P0141, P0155, P0161 [MZI-3.5]
WM: DTC P01XX

id0102d1855300

DTC P0135
P0135: Front HO2S heater (RH) circuit
DTC P0141
P0141: Rear HO2S heater (RH) circuit
DTC P0155
P0155: Front HO2S heater (LH) circuit
DTC P0161
P0161: Rear HO2S heater (LH) circuit
• During testing the heated oxygen sensor heaters are checked for open and short circuits and excessive
DETECTION
current draw.
CONDITION
• The test fails when the current draw exceeds a calibrated limit or an open or short circuit is detected.
• Short to ground between HO2S terminal A and HO2S terminal C
• Short to ground between HO2S terminal A and HO2S terminal D
• Short to ground between HO2S terminal A and HO2S terminal B
• Water in the wiring harness connector
• Open circuit between PCM terminal 2J and front HO2S (RH) terminal A
POSSIBLE
• Open circuit between PCM terminal 2AS and rear HO2S (RH) terminal A
CAUSE
• Open circuit between PCM terminal 2E and front HO2S (LH) terminal A
• Open circuit between PCM terminal 2AO and rear HO2S (LH) terminal A
• Low battery voltage
• Corrosion or incorrect harness connections
• HO2S heater malfunction

01-02–58
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0135 P0135: Front HO2S heater (RH) circuit
DTC P0141 P0141: Rear HO2S heater (RH) circuit
DTC P0155 P0155: Front HO2S heater (LH) circuit
DTC P0161 P0161: Rear HO2S heater (LH) circuit
MAIN RELAY NO.1
FRONT HO2S (LH) PCM
4 5 4 6 7 8 11
C 9 A 2E FRONT HO2S (LH) HEATER 01-02

4 11
10 B 2U FRONT HO2S (LH)

4
D

FRONT HO2S (RH)

4 5 4 6 7 8 11
C 9 A 2J FRONT HO2S (RH) HEATER

4 11
16
10 B 2Y FRONT HO2S (RH)

4 11
D 2AL

REAR HO2S (LH)

4 5 4 6 7 8 11
C 9 A 2AO REAR HO2S (LH) HEATER

4 11
10 B 2BC REAR HO2S (LH)

4
D

REAR HO2S (RH)

4 5 4 6 7 8 11
C 9 A 2AS REAR HO2S (RH) HEATER

4 11
10 B 2BG REAR HO2S (RH)

4
D

PCM
FRONT HO2S (LH, RH) REAR HO2S (LH, RH)
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE WIRING HARNESS-SIDE
CONNECTOR CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

C A C A
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
D B D B 2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–59
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ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT FOR SOURCE OF POTENTIAL HO2S Yes Repair the source of the contamination. Change the engine
CONTAMINATION oil and oil filter. Then go to the next step.
• Investigate the following items as potential No Go to the next step.
sources of HO2S contamination:
— Use of unapproved silicon sealers
— Fuel contaminated by silicon additives
— Excessive oil consumption
— Glycol leaking internally in the engine
— Lead-contaminated fuel
— Short drive cycles in cold weather
— Use of unapproved cleaning agents
• Is a concern present?
4 VISUALLY INSPECT HO2S WIRING HARNESS Yes Repair or replace suspected part, Then go to Step 12.
• Connect the PCM connector. No Go to the next step.
• Visually inspect the HO2S wiring harness for
exposed wiring water contamination, corrosion,
and proper assembly.
• Is a concern present?
5 INSPECT POWER SUPPLY IN WIRING Yes Turn the ignition switch off. Go to the next step.
HARNESS No Repair or replace suspected part, Go to Step 12.
• Disconnect suspect HO2S connector.
• Perform the KOEO self-test.
• Measure the voltage between suspect HO2S
connector terminal A and C, on the wiring
harness side.
• Is the voltage more than 10 V?
6 INSPECT HO2S HEATER FOR SHORT TO Yes Go to the next step.
GROUND No Repair or replace suspected part, Go to Step 12.
• Disconnect the PCM connector.
• Measure the resistance between HO2S
terminal A on the wiring harness side and body
ground.
• Is the resistance more than 10 kilohms?
7 INSPECT HO2S HEATER FOR SHORT IN Yes Go to the next step.
WIRING HARNESS No Repair or replace suspected part, Go to Step 12.
• Measure the resistance between the following
terminals:
— HO2S terminal A (wiring harness-side) and
HO2S terminal C (wiring harness-side)
— HO2S terminal A (wiring harness-side) and
HO2S terminal D (wiring harness-side)
— HO2S terminal A (wiring harness-side) and
HO2S terminal B (wiring harness-side)
• Are the resistances more than 10 kilohms?

01-02–60
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
8 INSPECT HO2S HEATER CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT IN WIRING HARNESS No Repair or replace suspected part, Go to Step 12.
• For DTC P0135, measure the resistance
between PCM terminal 2J and front HO2S
(RH) terminal A.
• For DTC P0141, measure the resistance
between PCM terminal 2AS and rear HO2S 01-02
(RH) terminal A.
• For DTC P0155, measure the resistance
between PCM terminal 2E and front HO2S
(LH) terminal A.
• For DTC P0161, measure the resistance
between PCM terminal 2AO and rear HO2S
(LH) terminal A.
• Is the resistance less than 5.0 ohms?
9 INSPECT INTERNAL RESISTANCE OF HO2S Yes Go to the next step.
HEATER No Replace HO2S.
• Measure the resistance between the suspect (See 01-40-20 FRONT HEATED OXYGEN SENSOR
HO2S terminal A and C, on the component (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
side. (See 01-40-23 REAR HEATED OXYGEN SENSOR (HO2S)
• Is the resistance between 3—30 ohms? REMOVAL/INSTALLATION [MZI-3.5].)
Go to Step 12.
10 INSPECT HO2S CASE FOR SHORT TO POWER Yes Go to the next step.
SUPPLY, HTR, AND SIGNRTN No Replace HO2S.
• Measure the resistance between the suspect (See 01-40-20 FRONT HEATED OXYGEN SENSOR
HO2S terminal A and D at component side. (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
• Measure the resistance between the suspect (See 01-40-23 REAR HEATED OXYGEN SENSOR (HO2S)
HO2S terminal A and body ground. INSPECTION [MZI-3.5].)
• Is the resistance more than 10 kilohms? Go to the next step.
11 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
12 VERIFY TROUBLESHOOTING OF MISFIRE DTC Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
13 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–61
1890-1U-06H(01-02).fm 62 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0148 [MZI-3.5]
id0102d1880600

DTC P0148 Fuel delivery error

DETECTION
• At least 1 bank is lean at wide open throttle (WOT).
CONDITION
• Severely restricted fuel filter
POSSIBLE • Severely restricted fuel supply line
CAUSE • Damaged or worn fuel pump
• Damaged or contaminated MAF sensor

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT SYSTEM INTEGRITY Yes Repair if necessary. Then go to Step 11.
• Visually inspect the complete fuel delivery No Go to the next step.
system for damage and leakage.
• Check the following:
— Fuel lines and connections
— Relays
— Fuel tank
— Fuel pump
— Fuel pressure regulator
— Fuel pulse damper
— Fuel rail at fuel injectors
— Damaged connector pins
— Electrical connectors not fully engaged
• Verify that the vehicle has followed the
maintenance schedule. A new fuel filter should
have been installed within the last 48,280 km
{29,934 mph}.
• Verify that the fuse integrity.
• Verify that the battery is fully charged.
• Verify that there is clean sufficient fuel.
• Is a concern present?
4 INSPECT ALL SYSTEM RELATED DEVICES Yes Go to the next step.
(SENSOR, DAMPER OR REGULATOR) FOR No If the vacuum line connected to a component indicates that
LEAKAGE a fuel leak is present, install a new component. Then go to
• Turn the ignition switch off. Step 11.
• Connect the fuel pump connector.
• Perform the KOER self-test.
• Check for manifold vacuum at each system
related component with a vacuum line.
• Turn the ignition switch off.
• Wait 10 s.
• Perform the KOER self-test.
• Run the engine for approx. 10 s.
• Turn the ignition switch off.
• Remove the vacuum hose on each system
device connected to the fuel rail.
• Inspect for the presence of fuel in the vacuum
line of each device connected to the fuel rail.
• Are all vacuum lines for system related devices
indicating no fuel present?

01-02–62
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT FUEL PRESSURE Yes Go to Step 9.
• Turn the ignition switch off. No Go to the next step.
• Relieve the fuel pressure. Refer to the
Workshop Manual Fuel System Pressure
Release procedure.
• Connect the mechanical fuel pressure gauge.
• Perform the KOEO self-test. 01-02
• Pressurize the fuel system. Refer to the
Workshop Fuel System for the Fuel System
Pressure Release procedure to pressurize the
fuel system.
• Compare the fuel pressure reading to the Fuel
System Specification Chart.
• Is the fuel pressure within range?
6 INSPECT FUEL PUMP GROUND CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT IN WIRING HARNESS No Repair or replace suspected part, Then go to Step 11.

Note
• Refer to the Wiring Diagrams Manual for
schematic and connector information.

• Disconnect the fuel pump connector.

• Measure the resistance between fuel pump
connector terminal D (wiring harness-side) and
body ground.
• Is the voltage less than 0.5 ohm?
7 INSPECT FUEL PUMP POWER SUPPLY Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT IN WIRING No Repair or replace suspected part, Then go to Step 11.
HARNESS
• Disconnect the fuel pump connector.
• Perform the KOEO self-test.
• Access the PCM and control the FP PID.
• Measure the voltage between fuel pump
connector terminal B (wiring harness-side) and
body ground.
• Is the voltage more than 10 V?
8 INSPECT FUEL PRESSURE LEAK Yes Perform the KOEO self-test. Go to Step 10.
No Go to the next step.
Note
• When the fuel pump is commanded off, the
fuel pressure may substantially decrease
and then stabilize.

Note
• During output state control, the fuel pump
stays commanded on for only approx. 5 s.

• Connect the mechanical fuel pressure gauge.

• Perform the KOEO self-test.
• Access the PCM and control the FP PID.
• Run the fuel pump to obtain maximum fuel
pressure.
• Command the fuel pump off.
• Allow the fuel pressure to stabilize.
• Record the stabilized reading.
• Monitor the fuel pressure for 1 min.
• Does the fuel pressure remain within 34 kPa
{255 mmHg, 10.0 inHg} of the recorded
reading after 1 min?
9 INSPECT FUEL INJECTOR OPERATION Yes Go to the next step.
• Remove the fuel injector. No Replace the fuel injector, then go to Step 11.
• Inspect the fuel injector operation.
• Is the fuel injector normal?

01-02–63
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
10 INSPECT FUEL SUPPLY LINE FOR Yes Replace the fuel pump module. Then go to the next step.
RESTRICTION No Repair the cause of the restriction. Then go to the next
step.
Note
• Observe the Warnings, Cautions, and
Notes.

• Disconnect the fuel supply line at the fuel rail.

• Disconnect the fuel supply line at the fuel
pump.
• Check the fuel supply line for restriction.
• Apply 21—34 kPa {2142—3467 mmHg,
84.34—136.4 inHg} air pressure to the fuel
supply line.
• Does air flow freely through the line?
11 VERIFY TROUBLESHOOTING OF DTC P0148 Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
12 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–64
1890-1U-06H(01-02).fm 65 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0171, P0174 [MZI-3.5]
id0102d1880400

DTC P0171P0171: System too lean (RH)

DTC P0174P0174: System too lean (LH)
• P0171 indicates that the fuel/air ratio is too lean (RH).
DETECTION • P0174 indicates that the fuel/air ratio is too lean (LH).
CONDITION • The adaptive fuel strategy continuously monitors the fuel delivery hardware. The test fails when the
adaptive fuel tables reach a rich calibrated limit.
01-02
Fuel System:
• Damaged or leaking fuel pulse damper
• Fuel filter plugged or dirty
• Damaged or worn fuel pump
• Leaking fuel pump check valve
• Leaking/contaminated fuel injectors
• Low fuel pressure or running out of fuel
• Purge solenoid valve is leaking when the canister is clean
POSSIBLE • Fuel supply line restricted
CAUSE • Fuel rail pressure sensor bias
Exhaust System:
• Exhaust leaks in the exhaust manifold gasket or mating gaskets before or near the HO2S
Intake Air System:
• Air leaks after the MAF sensor
• Vacuum leaks
• PCV system is leaking or the valve is stuck open
• Improperly seated engine oil dipstick
• Damaged or contaminated MAF sensor

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting procedures.
STORED DTCS (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related PENDING CODE or stored
DTCs.
• Are any DTCs present other than the following:
— P0171, P0174, P2195 or P2197?
4 PERFORM VISUAL INSPECTION ON Yes Repair if necessary. Then go to Step 7.
INTAKEAIR SYSTEM AND ALL VACUUM No Go to the next step.
HOSES
• Turn the ignition switch off.
• Check the intake air system for leaks,
obstructions, and damage.
• Inspect the entire length of all the vacuum
hoses for:
— Proper connections
— Damage or cracks
— Damaged or cracked vacuum vacuum hose
joint
• Verify the integrity of the positive crankcase
ventilation system.
• Verify that the PCV valve part number is
correct.
• Is a concern present?

01-02–65
1890-1U-06H(01-02).fm 66 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT FOR PRESENCE OF VACUUM LEAK Yes No vacuum leak is present. Go to Step 8.
No Go to the next step.
Note
• Fuel trim values at idle are more sensitive to
a vacuum leak. The vacuum leak
(unmetered air) represents a larger portion
of the total air flow at idle than at part
throttle.
• The BARO PID is not a commended PID to
monitor when diagnosing a vacuum leak.
BARO is calculated during high engine load,
when the vacuum leak represents a small
portion of the total air flow
• When calculating the total fuel correction in
the following steps, if LONGFT1 equals
+13% and SHRTFT1 equals +23%, the total
fuel correction for bank 1 equals +36%. If
LONGFT2 equals +24% and SHRTFT2
equals -3% the total fuel correction for bank
2 equals +21%.
• If the freeze frame ECT PID is available,
stabilize the engine at the temperature
recorded by the freeze frame ECT PID. If the
freeze frame ECT PID is not available,
maintain the engine coolant temperature
between 82—101 °C {180—215 °F} and the
intake air temperature at less than 46 °C
{115 °F}.

• Perform the KOER self-test.

• Access the PCM and monitor the ECT, CHT
and IAT PIDs.
• Access the PCM and monitor the LONGFT1,
SHRTFT1, LONGFT2 and SHRTFT2 PIDs.
• Allow the engine to stabilize at the temperature
necessary to recreate the concern.
• Add and record the LONGFT PID value to the
SHRTFT PID value for each bank, correction at
idle.
• Increase the engine speed to 2,500 rpm for 10
s. Record the LONGFT1, SHRTFT1,
LONGFT2, and system SHRTFT2 PID values.
• Add and record the LONGFT PID value to the
SHRTFT PID value for each bank, correction at
2,500 rpm.
• Is the total fuel correction value difference
between idle and 2,500 rpm less than 15%?

01-02–66
1890-1U-06H(01-02).fm 67 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
6 LOCATE VACUUM LEAK Yes Repair if necessary. Then go to the next step.
Caution No Inspect the intake air system for a vacuum leak in the intake
• Do not clamp or pinch a hard plastic manifold or intake gaskets. Repair if necessary. Then go to
hose. Use a vacuum cap or equivalent to the next step.
restrict the hose.

Note 01-02
• Restricting the EVAP vapor hose while the
EVAP emission canister is purging may shift
the SHRTFT. Perform a visual inspection if
necessary.
• When monitoring for a decrease in the
SHRTFT PIDs in the following steps, if
SHRTFT1 equals +15% and the hose is
restricted, SHRTFT1 decreases to -7%. The
total decrease in the SHRTFT PIDs equals
22%.

• Locate the vacuum hose joint for the intake air

and PCV systems.
• Access the PCM and monitor the SHRTFT1
and SHRTFT2 PIDs.
• Restrict the vacuum lines one at a time for 30 s.
If a vacuum leak in the intake is present, the
SHRTFT PID values decrease as the hose is
restricted.
• Is the decrease in the SHRTFT PIDs more than
15% when one of the vacuum hoses is
restricted?
7 VACUUM LEAK REPAIR VERIFICATION Yes Reset the keep alive memory. Then go to Step 13.
No A vacuum leak is still present. Go to Step 6.
Note
• If the freeze frame ECT PID is available,
stabilize the engine at the temperature
recorded by the freeze frame ECT PID. If the
freeze frame ECT PID is not available,
maintain the engine coolant temperature
between 82—101 °C {180—215 °F} and the
intake air temperature less than 46 °C {115
°F}.

• Access the PCM and monitor the SHRTFT1

and SHRTFT2 PIDs.
• Allow the engine to stabilize at the temperature
necessary to recreate the concern.
• Record the SHRTFT1 and SHRTFT2 PID
values.
• Turn the ignition switch off.
• Repair the vacuum leak.
• Perform the KOER self-test.
• Allow the engine to stabilize at the temperature
necessary to recreate the concern.
• Access the PCM and monitor the SHRTFT1
and SHRTFT2 PIDs.
• Compare the recorded SHRTFT PID values,
prior to the no vacuum leak repair, to the
current SHRTFT PID values.
• Is the decrease in the SHRTFT PIDs more than
15%?

01-02–67
1890-1U-06H(01-02).fm 68 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
8 INSPECT FUEL PRESSURE Yes Go to Step 10.
No Go to the next step.
Warning
• Fuel line spills and leakage are
dangerous. Fuel can ignite and cause
serious injuries or death. Fuel can also
irritate skin and eyes. To prevent this,
always complete the “BEFORE REPAIR
PROCEDURE”.

Note
• For vehicle specific fuel pressure ranges,
refer to the “FUEL LINE PRESSURE
INSPECTION”.

• Remove the jumper wire(s).

• Connect the HO2S connector.
• Relieve the fuel pressure.
• Connect the mechanical fuel pressure gauge.
• Pressurize the fuel system.
• Perform the KOER self-test.
• Allow the fuel pressure to stabilize.
• Turn the ignition switch off.
• Access the PCM and control the FP PID.
• Run the fuel pump to obtain maximum fuel
pressure.
• Is the fuel pressure within the range for the
vehicle being diagnosed?
9 INSPECT FUEL LINE FROM FUEL PUMP TO Yes Replace suspected fuel line. Then go to Step 13.
FUEL DELIVERY PIPE No Inspect the low-pressure side fuel filter for the following:
• Visually inspect fuel line for any leakage. • Foreign materials or stain inside fuel filter. Perform the
• Is fuel leakage found? following actions as a result.
• If foreign material or staining is found inside the fuel
filter (low-pressure side), clean the fuel tank and filter.
• If normal, replace fuel pump unit.
Then go to Step 13.
10 INSPECT FUEL INJECTOR OPERATION Yes Go to the next step.
• Remove fuel injector. No Replace the fuel injector, then go to Step 13.
• Inspect the injector operation.
• Is the fuel injector normal?
11 INSPECT HO2S OUTPUT VOLTAGE Yes Go to the next step.
• Visually inspect the HO2S circuit for exposed No Replace the HO2S. Then go to Step 13.
wiring, contamination, corrosion and correct
assembly. Repair if necessary.
• Measure the voltage between HO2S terminal B
and D on the component side.
• Increase the engine speed to 2,000 rpm for 3
min.
• Perform the KOER self-test.
• Monitor the signal voltage during the self-test.
• Is the voltage more than 0.5 V at any time
during the self-test?
12 PERFORM THOROUGH WIGGLE TEST ON Yes Isolate the concern and repair if necessary. Then go to the
HO2S WIRING HARNESS next step.
• Turn the ignition switch off. No Go to the next step.
• Connect the HO2S connector.
• Perform the KOER self-test
• Verify that the engine is at normal operating
temperature.
• Access the PCM and monitor the HO2S signal
PID.
• Wiggle, shake, and bend small sections of the
wiring harness while working from the sensor
to the PCM.
• While monitoring the HO2S PID, does the
HO2S stop switching?

01-02–68
1890-1U-06H(01-02).fm 69 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
13 VERIFY TROUBLESHOOTING OF DTC P0171, Yes Replace PCM, then go to the next step.
P0174 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using 01-02
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
14 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P0172, P0175 [MZI-3.5]
id0102d1880500

DTC P0172P0172: System too rich (RH)

DTC P0175P0175: System too rich (LH)
• P0172 indicates that the fuel/air ratio is too rich (RH).
DETECTION • P0175 indicates that the fuel/air ratio is too rich (LH).
CONDITION • The adaptive fuel strategy continuously monitors the fuel delivery hardware. The test fails when the
adaptive fuel tables reach a rich calibrated limit.
Fuel System:
• Damaged or leaking fuel pulse damper
• Leaking fuel injectors
• Fuel return line restricted
POSSIBLE • Fuel rail pressure sensor bias
CAUSE • Purge solenoid valve is leaking when the canister is full
Base engine:
• Engine oil contamination
Intake Air System:
• Damaged or contaminated MAF sensor

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting procedures.
STORED DTCS (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related PENDING CODE or stored
DTCs.
• Are any DTCs present other than the following:
— P0172, P0175, P2196 or P2198?
4 INSPECT ENTIRE INTAKE AIR SYSTEM FOR Yes Repair if necessary.
DEBRIS, BLOCKAGE OR OTHER DAMAGE Then go to Step 9.
• Check the intake air system for obstructions, No Go to the next step.
restrictions, and damage.
• Check the throttle plate for obstructions or
sludge.
• Check the air filter element and housing for
blockage.
• Is a concern present?

01-02–69
1890-1U-06H(01-02).fm 70 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT FUEL PRESSURE Yes Go to the next step.
No Replace the fuel pump unit.
Warning Then go to Step 9.
• Fuel line spills and leakage are
dangerous. Fuel can ignite and cause
serious injuries or death. Fuel can also
irritate skin and eyes. To prevent this,
always complete the “BEFORE REPAIR
PROCEDURE”.

Note
• For vehicle specific fuel pressure ranges,
refer to the “FUEL LINE PRESSURE
INSPECTION”.

• Remove the jumper wire(s).

• Connect the HO2S connector.
• Relieve the fuel pressure.
• Connect the mechanical fuel pressure gauge
• Pressurize the fuel system.
• Perform the KOER self-test.
• Allow the fuel pressure to stabilize.
• Turn the ignition switch off.
• Perform the KOER self-test.
• Access the PCM and control the FP PID.
• Run the fuel pump to obtain maximum fuel
pressure.
• Is the fuel pressure within the range for the
vehicle being diagnosed?
6 INSPECT FUEL INJECTOR OPERATION Yes Go to the next step.
• Remove fuel injector. No Replace the fuel injector.
• Inspect the injector operation. Then go to Step 9.
• Is the fuel injector normal?
7 INSPECT HO2S OUTPUT VOLTAGE Yes Go to the next step.
• Visually inspect the HO2S circuit for exposed No Replace the HO2S.
wiring, contamination, corrosion and correct Then go to Step 9.
assembly. Repair if necessary.
• Measure the voltage between HO2S terminal B
and D on the component side.
• Increase the engine speed to 2,000 rpm for 3
min.
• Perform the KOER self-test.
• Monitor the signal voltage during the self-test.
• Is the voltage more than 0.5 V at any time
during the self-test?
8 PERFORM THOROUGH WIGGLE TEST ON Yes Isolate the concern and repair if necessary.
HO2S WIRING HARNESS Then go to the next step.
• Turn the ignition switch off. No Go to the next step.
• Connect the HO2S connector.
• Perform the KOER self-test.
• Verify that the engine is at normal operating
temperature.
• Access the PCM and monitor the HO2S signal
PID.
• Wiggle, shake, and bend small sections of the
wiring harness while working from the sensor
to the PCM.
• While monitoring the HO2S PID, does the
HO2S stop switching?

01-02–70
1890-1U-06H(01-02).fm 71 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 VERIFY TROUBLESHOOTING OF DTC P0172, Yes Replace the PCM, then go to the next step.
P0175 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using 01-02
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P0201 [MZI-3.5]
WM: DTC P02XX

id0102d1805600

DTC P0201 Injector circuit/open—cylinder No.1

DETECTION • The CCM monitors the operation of the fuel injector drivers in the PCM. The test fails if the fuel injector
CONDITION circuitry is inoperative.
• Fuel injector No.1 malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit between fuel pump relay and fuel injector No.1 terminal B
• Open circuit between fuel injector No.1 terminal A and PCM terminal 2BJ
FUEL INJECTOR NO.1 FUEL PUMP RELAY PCM

7
3 5
B

3 6 4
A 2BJ

PCM
WIRING HARNESS-SIDE CONNECTOR

FUEL INJECTOR NO.1

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

A
B 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–71
1890-1U-06H(01-02).fm 72 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.
3 INSPECT FUEL INJECTOR NO.1 CONNECTOR Yes Repair or replace suspected part, then go to Step 8.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel injector No.1 connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there malfunction?
5 INSPECT FUEL INJECTOR NO.1 POWER Yes Go to the next step.
SUPPLY CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between fuel injector No.1
connector terminal B and body ground.
• Is the voltage B+?
6 INSPECT FUEL INJECTOR NO.1 SIGNAL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Inspect continuity between fuel injector No.1
terminal A (wiring harness-side) and PCM
terminal 2BJ (wiring harness-side).
• Is there continuity?
7 INSPECT FUEL INJECTOR NO.1 Yes Replace the fuel injector No.1, then go to the next step.
• Inspect the fuel injector No.1. No Go to the next step.
(See 01-14-25 FUEL INJECTOR INSPECTION
[MZI-3.5].)
• Is there any malfunction?
8 VERIFY TROUBLESHOOTING OF DTC P0201 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–72
1890-1U-06H(01-02).fm 73 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0202 [MZI-3.5]
id0102d1805700

DTC P0202 Injector circuit/open—cylinder No.2

DETECTION • The CCM monitors the operation of the fuel injector drivers in the PCM. The test fails if the fuel injector
CONDITION circuitry is inoperative.
• Fuel injector No.2 malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit between fuel pump relay and fuel injector No.2 terminal B 01-02
• Open circuit between fuel injector No.2 terminal A and PCM terminal 2BM
FUEL INJECTOR NO.2 FUEL PUMP RELAY PCM

7
3 5
B

3 6 4
A 2BM

PCM
WIRING HARNESS-SIDE CONNECTOR

FUEL INJECTOR NO.2

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

A
B 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.
3 INSPECT FUEL INJECTOR NO.2 CONNECTOR Yes Repair or replace suspected part, then go to Step 8.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel injector No.2 connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there malfunction?

01-02–73
1890-1U-06H(01-02).fm 74 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT FUEL INJECTOR NO.2 POWER Yes Go to the next step.
SUPPLY CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between fuel injector No.2
connector terminal B and body ground.
• Is the voltage B+?
6 INSPECT FUEL INJECTOR NO.2 SIGNAL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Inspect continuity between fuel injector No.2
terminal A (wiring harness-side) and PCM
terminal 2BM (wiring harness-side).
• Is there continuity?
7 INSPECT FUEL INJECTOR NO.2 Yes Replace the fuel injector No.2, then go to the next step.
• Inspect the fuel injector No.2. No Go to the next step.
(See 01-14-25 FUEL INJECTOR INSPECTION
[MZI-3.5].)
• Is there any malfunction?
8 VERIFY TROUBLESHOOTING OF DTC P0202 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–74
1890-1U-06H(01-02).fm 75 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0203 [MZI-3.5]
id0102d1805800

DTC P0203 Injector circuit/open—cylinder No.3

DETECTION • The CCM monitors the operation of the fuel injector drivers in the PCM. The test fails if the fuel injector
CONDITION circuitry is inoperative.
• Fuel injector No.3 malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit between fuel pump relay and fuel injector No.3 terminal B 01-02
• Open circuit between fuel injector No.3 terminal A and PCM terminal 2BF
FUEL INJECTOR NO.3 FUEL PUMP RELAY PCM

7
3 5
B

3 6 4
A 2BF

PCM
WIRING HARNESS-SIDE CONNECTOR

FUEL INJECTOR NO.3

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

A
B 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.
3 INSPECT FUEL INJECTOR NO.3 CONNECTOR Yes Repair or replace suspected part, then go to Step 8.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel injector No.3 connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there malfunction?

01-02–75
1890-1U-06H(01-02).fm 76 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT FUEL INJECTOR NO.3 POWER Yes Go to the next step.
SUPPLY CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between fuel injector No.3
connector terminal B and body ground.
• Is the voltage B+?
6 INSPECT FUEL INJECTOR NO.3 SIGNAL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Inspect continuity between fuel injector No.3
terminal A (wiring harness-side) and PCM
terminal 2BF (wiring harness-side).
• Is there continuity?
7 INSPECT FUEL INJECTOR NO.3 Yes Replace the fuel injector No.3, then go to the next step.
• Inspect the fuel injector No.3. No Go to the next step.
(See 01-14-25 FUEL INJECTOR INSPECTION
[MZI-3.5].)
• Is there any malfunction?
8 VERIFY TROUBLESHOOTING OF DTC P0203 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–76
1890-1U-06H(01-02).fm 77 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0204 [MZI-3.5]
id0102d1805900

DTC P0204 Injector circuit/open—cylinder No.4

DETECTION • The CCM monitors the operation of the fuel injector drivers in the PCM. The test fails if the fuel injector
CONDITION circuitry is inoperative.
• Fuel injector No.4 malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit between fuel pump relay and fuel injector No.4 terminal B 01-02
• Open circuit between fuel injector No.4 terminal A and PCM terminal 2BH
FUEL INJECTOR NO.4 FUEL PUMP RELAY PCM

7
3 5
B

3 6 4
A 2BH

PCM
WIRING HARNESS-SIDE CONNECTOR

FUEL INJECTOR NO.4

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

A
B 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.
3 INSPECT FUEL INJECTOR NO.4 CONNECTOR Yes Repair or replace suspected part, then go to Step 8.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel injector No.4 connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there malfunction?

01-02–77
1890-1U-06H(01-02).fm 78 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT FUEL INJECTOR NO.4 POWER Yes Go to the next step.
SUPPLY CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between fuel injector No.4
connector terminal B and body ground.
• Is the voltage B+?
6 INSPECT FUEL INJECTOR NO.4 SIGNAL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Inspect continuity between fuel injector No.4
terminal A (wiring harness-side) and PCM
terminal 2BH (wiring harness-side).
• Is there continuity?
7 INSPECT FUEL INJECTOR NO.4 Yes Replace the fuel injector No.4, then go to the next step.
• Inspect the fuel injector No.4. No Go to the next step.
(See 01-14-25 FUEL INJECTOR INSPECTION
[MZI-3.5].)
• Is there any malfunction?
8 VERIFY TROUBLESHOOTING OF DTC P0204 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–78
1890-1U-06H(01-02).fm 79 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0205 [MZI-3.5]
id0102d1819400

DTC P0205 Injector circuit/open—cylinder No.5

DETECTION • The CCM monitors the operation of the fuel injector drivers in the PCM. The test fails if the fuel injector
CONDITION circuitry is inoperative.
• Fuel injector No.5 malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit between fuel pump relay and fuel injector No.5 terminal B 01-02
• Open circuit between fuel injector No.5 terminal A and PCM terminal 2BB
FUEL INJECTOR NO.5 FUEL PUMP RELAY PCM

7
3 5
B

3 6 4
A 2BB

PCM
WIRING HARNESS-SIDE CONNECTOR

FUEL INJECTOR NO.5

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

A
B 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.
3 INSPECT FUEL INJECTOR NO.5 CONNECTOR Yes Repair or replace suspected part, then go to Step 8.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel injector No.5 connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there malfunction?

01-02–79
1890-1U-06H(01-02).fm 80 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT FUEL INJECTOR NO.5 POWER Yes Go to the next step.
SUPPLY CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between fuel injector No.5
connector terminal B and body ground.
• Is the voltage B+?
6 INSPECT FUEL INJECTOR NO.5 SIGNAL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Inspect continuity between fuel injector No.5
terminal A (wiring harness-side) and PCM
terminal 2BB (wiring harness-side).
• Is there continuity?
7 INSPECT FUEL INJECTOR NO.5 Yes Replace the fuel injector No.5, then go to the next step.
• Inspect the fuel injector No.5. No Go to the next step.
(See 01-14-25 FUEL INJECTOR INSPECTION
[MZI-3.5].)
• Is there any malfunction?
8 VERIFY TROUBLESHOOTING OF DTC P0205 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–80
1890-1U-06H(01-02).fm 81 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0206 [MZI-3.5]
id0102d1819500

DTC P0206 Injector circuit/open—cylinder No.6

DETECTION • The CCM monitors the operation of the fuel injector drivers in the PCM. The test fails if the fuel injector
CONDITION circuitry is inoperative.
• Fuel injector No.6 malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit between fuel pump relay and fuel injector No.6 terminal B 01-02
• Open circuit between fuel injector No.6 terminal A and PCM terminal 2BD
FUEL INJECTOR NO.6 FUEL PUMP RELAY PCM

7
3 5
B

3 6 4
A 2BD

PCM
WIRING HARNESS-SIDE CONNECTOR

FUEL INJECTOR NO.6

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

A
B 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.
3 INSPECT FUEL INJECTOR NO.6 CONNECTOR Yes Repair or replace suspected part, then go to Step 8.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel injector No.6 connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there malfunction?

01-02–81
1890-1U-06H(01-02).fm 82 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT FUEL INJECTOR NO.6 POWER Yes Go to the next step.
SUPPLY CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between fuel injector No.6
connector terminal B and body ground.
• Is the voltage B+?
6 INSPECT FUEL INJECTOR NO.6 SIGNAL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Inspect continuity between fuel injector No.6
terminal A (wiring harness-side) and PCM
terminal 2BD (wiring harness-side).
• Is there continuity?
7 INSPECT FUEL INJECTOR NO.6 Yes Replace the fuel injector No.6, then go to the next step.
• Inspect the fuel injector No.6. No Go to the next step.
(See 01-14-25 FUEL INJECTOR INSPECTION
[MZI-3.5].)
• Is there any malfunction?
8 VERIFY TROUBLESHOOTING OF DTC P0206 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
SOKYU_WM: DTC P02XX

01-02–82
1890-1U-06H(01-02).fm 83 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0222 [MZI-3.5]
id0102d1806000

DTC P0222 TP sensor No.2 circuit low input

DETECTION
• The TP sensor No.2 circuit was flagged as a concern by the PCM indicating a low voltage or open circuit.
CONDITION
• TP sensor No.2 malfunction
• Connector or terminal malfunction
POSSIBLE
• Open circuit between throttle body terminal C and PCM terminal 2AD 01-02
CAUSE
• Short to ground circuit between throttle body terminal C and PCM terminal 2AD
• Open circuit between throttle body terminal E and PCM terminal 2AH
TP SENSOR NO.2 (THROTTLE BODY) PCM

8
3 5
D 2D

3 4 6 5
C 2AD

3 7 5
E 2AH

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT TP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 9.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the throttle body connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–83
1890-1U-06H(01-02).fm 84 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT TP SENSOR CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to Step 9.
GROUND No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect for continuity between the following
circuits:
— TP sensor terminal D (wiring harness-side)
and body ground
— TP sensor terminal C (wiring harness-side)
and body ground
• Are there continuity?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT TP SIGNAL CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Inspect for continuity between throttle body
connector terminal C (wiring harness-side) and
PCM terminal 2AD (wiring harness-side).
• Is there continuity?
7 INSPECT TP GROUND CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Turn the ignition switch off.
• Verify the continuity between TP sensor
terminal E and body ground.
• Is the continuity?
8 INSPECT TP SENSOR NO.2 Yes Replace the throttle body, then go to the next step.
• Inspect the TP sensor No.2. No Go to the next step.
(See 01-40-12 THROTTLE POSITION (TP)
SENSOR INSPECTION [MZI-3.5].)
• Is there any malfunction?
9 VERIFY TROUBLESHOOTING OF DTC P0222 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–84
1890-1U-06H(01-02).fm 85 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0223 [MZI-3.5]
id0102d1806100

DTC P0223 TP sensor No.2 circuit high input

DETECTION
• The TP sensor No.2 circuit was flagged as a concern by the PCM indicating a high voltage.
CONDITION
• TP sensor No.2 malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit wiring harness between throttle body terminal C and PCM terminal 2AD 01-02
• TP sensor signal circuits are shorted each other
TP SENSOR NO.2
(THROTTLE BODY) PCM

7
3 6 4
D 2D

3 6 4
C 2AD

3 4
E 2AH

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT TP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 8.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the throttle body connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–85
1890-1U-06H(01-02).fm 86 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
5 INSPECT TP SIGNAL CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Disconnect the throttle body connector.
• Inspect for continuity between the following
terminals:
— Throttle body terminal C and PCM terminal
2AD
— Throttle body terminal D and PCM terminal
2D
• Are there continuity?
6 INSPECT TP SENSOR NO.2 Yes Replace the throttle body, then go to Step 8.
• Inspect the TP sensor No.2. No Go to the next step.
(See 01-40-12 THROTTLE POSITION (TP)
SENSOR INSPECTION [MZI-3.5].)
• Is there any malfunction?
7 INSPECT TP SENSOR SIGNAL CIRCUITS FOR Yes Go to the next step.
SHORT EACH OTHER No Repair or replace suspected part, then go to Step 8.
• Disconnect the TP sensor and PCM connector.
• Measure resistance between Throttle body
connector terminal D and C.
• Is the resistance more than 10 kilohms?
8 VERIFY TROUBLESHOOTING OF DTC P0223 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P02XX

01-02–86
1890-1U-06H(01-02).fm 87 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0230 [MZI-3.5]
id0102d1819700

DTC P0230FP primary circuit

• The PCM monitors the fuel pump circuit output from the PCM. The test fails when the fuel pump output is
commanded ON (grounded) and excessive current draw is detected on the fuel pump circuit. The test also
DETECTION
fails when the fuel pump output is commanded OFF and voltage is not detected on the fuel pump circuit.
CONDITION
The PCM expects to detect vehicle power voltage coming through the fuel pump relay coil to the fuel pump
circuit.
01-02
• Fuel pump relay malfunction
• Connector or terminal malfunction
POSSIBLE • Open circuit wiring harness between fuel pump relay terminal E and PCM terminal 1V
CAUSE • Short to ground circuit between fuel pump relay terminal E and PCM terminal 1V
• Open circuit wiring harness between ignition switch and fuel pump relay terminal A
• PCM malfunction
BATTERY IGNITION SWITCH

4 4 6
C A

B 9 FUEL PUMP RELAY

FUEL PUMP M D E
PCM
4 4 7 8
D 5
1V FUEL PUMP

5 FUEL PUMP
1Q MONITOR

PCM
WIRING HARNESS-SIDE CONNECTOR
FUEL PUMP UNIT
FUEL PUMP RELAY
WIRING HARNESS-SIDE CONNECTOR

A E 1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C
C C A
D B
D 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC inspection.
STORED DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Verify the related PENDING CODE or stored No Go to the next step.
DTCs.
• Are other DTCs present?

01-02–87
1890-1U-06H(01-02).fm 88 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT FUEL PUMP RELAY CONNECTOR Yes Repair or replace suspected part, then go to Step 10.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel pump relay.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
6 INSPECT FUEL PUMP RELAY POWER SUPPLY Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between fuel pump relay
connector terminal A (harness-side) and body
ground.
• Is voltage B+?
7 INSPECT FUEL PUMP CONTROL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 10.
SHORT TO GROUND No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect for continuity between fuel pump relay
connector terminal E (harness-side) and body
ground.
• Is there continuity?
8 INSPECT FUEL PUMP CONTROL CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch off.
• Inspect for continuity between fuel pump relay
terminal E and PCM terminal 1V.
• Is there continuity?
9 INSPECT FUEL PUMP RELAY Yes Replace the fuel pump relay, then go to the next step.
• Inspect the fuel pump relay. No Go to the next step.
(See 09-21-6 RELAY INSPECTION.)
• Is there any malfunction?
10 VERIFY TROUBLESHOOTING OF DTC P0230 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–88
1890-1U-06H(01-02).fm 89 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0231 [MZI-3.5]
id0102d1819800

DTC P0231 FP secondary circuit low

DETECTION • The PCM monitors the fuel pump monitor circuit. The test fails if the PCM commands the fuel pump ON
CONDITION and B+ voltage is not detected on the FPM circuit.
• Fuel pump relay malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit between battery and fuel pump relay terminal C 01-02
• Open circuit between fuel pump relay terminal D and PCM terminal 1Q
BATTERY IGNITION SWITCH

4 4
C A

B 8 FUEL PUMP RELAY

FUEL PUMP M D E
PCM
4 34
D 5
1V FUEL PUMP

7 5 FUEL PUMP
1Q MONITOR

PCM
WIRING HARNESS-SIDE CONNECTOR
FUEL PUMP UNIT
FUEL PUMP RELAY
WIRING HARNESS-SIDE CONNECTOR

A E 1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C
C C A
D B
D 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC inspection.
STORED DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Verify the related PENDING CODE or stored No Go to the next step.
DTCs.
• Are other DTCs present?

01-02–89
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT FUEL PUMP RELAY CONNECTOR Yes Repair or replace suspected part, then go to Step 9.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel pump relay.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
6 INSPECT FUEL PUMP RELAY POWER SUPPLY Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between fuel pump relay
connector terminal C (wiring harness-side) and
body ground.
• Is voltage B+?
7 INSPECT FUEL PUMP MONITOR CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Turn the ignition switch off.
• Inspect continuity between fuel pump relay
terminal D (wiring harness-side) and PCM
terminal 1Q (wiring harness-side).
• Is there continuity?
8 INSPECT FUEL PUMP RELAY Yes Replace the fuel pump relay, then go to the next step.
• Inspect the fuel pump relay. No Go to the next step.
(See 09-21-6 RELAY INSPECTION.)
• Is there any malfunction?
9 VERIFY TROUBLESHOOTING OF DTC P0231 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–90
1890-1U-06H(01-02).fm 91 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0232 [MZI-3.5]
id0102d1819900

DTC P0232FP secondary circuit high

• The PCM monitors the fuel pump monitor circuit. This test fails when the PCM detects voltage on the fuel
pump monitor circuit while the fuel pump is commanded OFF. The fuel pump monitor circuit is wired to a
DETECTION pull-up voltage inside the PCM. The fuel pump monitor circuit goes high if, with the key ON, engine OFF
CONDITION and the fuel pump commanded OFF, the fuel pump monitor/fuel pump power circuit loses its path to ground
through the fuel pump. The fuel pump monitor circuit also goes high if the fuel pump monitor/fuel pump
power circuit is short to voltage.
01-02
• Fuel pump relay malfunction
• Fuel pump malfunction
• Connector or terminal malfunction
POSSIBLE
• Open circuit between fuel pump terminal B and PCM terminal 1Q
CAUSE
• Fuel pump connector for poor connection
• Short to power supply between fuel pump terminal B and PCM terminal 1Q
• Short to power supply between fuel pump relay terminal D and PCM terminal 1Q
BATTERY IGNITION SWITCH

4 4
6 67
C A

9 B 8 FUEL PUMP RELAY

M D E
PCM
4 34
D 5
6 1V FUEL PUMP

5 FUEL PUMP
1Q MONITOR

PCM
WIRING HARNESS-SIDE CONNECTOR
FUEL PUMP UNIT
FUEL PUMP RELAY
WIRING HARNESS-SIDE CONNECTOR

A E 1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C
C C A
D B
D 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to the next step.
• Is any related Service Bulletins available? No Go to the next step.

01-02–91
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC inspection.
STORED DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Verify the related PENDING CODE or stored No Go to the next step.
DTCs.
• Are other DTCs present?
4 INSPECT FUEL PUMP RELAY CONNECTOR Yes Repair or replace suspected part, then go to Step 10.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel pump relay.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there malfunction?
6 INSPECT FUEL PUMP MONITOR CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 10.
SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between the following
terminals:
— Fuel pump relay terminal D (wiring harness-
side) and body ground
— fuel pump terminal B (wiring harness-side)
and body ground
• Is voltage B+?
7 INSPECT FUEL PUMP MONITOR CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch off.
• Inspect continuity between fuel pump terminal
B (wiring harness-side) and PCM terminal 1Q
(wiring harness-side).
• Is there continuity?
8 INSPECT FUEL PUMP RELAY Yes Replace the fuel pump relay, then go to Step 10.
• Inspect the fuel pump relay. No Go to the next step.
(See 09-21-6 RELAY INSPECTION.)
• Is there any malfunction?
9 INSPECT FUEL PUMP Yes Replace the fuel pump unit, then go to the next step.
• Inspect the fuel pump. No Go to the next step.
(See 01-14-19 FUEL PUMP UNIT
INSPECTION [MZI-3.5].)
• Is there any malfunction?
10 VERIFY TROUBLESHOOTING OF DTC P0232 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear DTC from memory using M-MDS.
• Start the engine.
• Perform the “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–92
1890-1U-06H(01-02).fm 93 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0297 [MZI-3.5]
id0102d1820000

DTC P0297 Vehicle over speed condition

DETECTION • P0297 indicates that the vehicle has been operated in a manner which caused the engine or vehicle to
CONDITION exceed a calibration limit.
• Wheel slippage (water, ice, mud and snow).
POSSIBLE
• Excessive engine rpm in neutral.
CAUSE
• Vehicle drive at a high rate of speed. 01-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT VEHICLE OPERATION Yes Vehicle is normal. Then go to the next step.
• Check for: No Clear DTCs and refer to “DIAGNOSTIC INDEX” if customer
— Water, ice, mud and snow causing wheel had any drive ability concerns.
slippage. (See 01-03-5 QUICK DIAGNOSTIC CHART [MZI-3.5].)
— Excessive engine speed in N (Neutral).
— Check whether the vehicle way driven at a
high rate of speed.
• Was the vehicle driven under any of the above
conditions?
4 VERIFY TROUBLESHOOTING OF DTC P0297 Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
SOKYU_WM: DTC P03XX

01-02–93
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0300 [MZI-3.5]
id0102d1806500

DTC P0300 Random misfire detected

• The PCM monitors the crankshaft position sensor input signal interval time. The PCM calculates the
change of the interval time for each cylinder. If the change of interval time exceeds the pre-programmed
criteria, the PCM detects a misfire in the corresponding cylinder. When the engine is running, the PCM
DETECTION
counts the number of misfires that occurred at 200 crankshaft revolutions and 1,000 crankshaft revolutions
CONDITION
and calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the pre-programmed
criteria, the PCM determines that a misfire, which can damage the catalytic converter or affect emission
performance, has occurred.
• CMP sensor malfunction
• CKP sensor malfunction
• Ignition coil malfunction
• Ignition system malfunction
• MAF sensor contamination
• Excess air suction in intake air system (between MAF/IAT sensor and dynamic chamber)
• Vacuum hoses damages or improper connection
• Fuel pump malfunction
• Fuel pressure regulator malfunction
POSSIBLE • Fuel line clogged
CAUSE • Fuel filter clogged
• Fuel runout
• Poor quality fuel
• Fuel leakage in fuel line
• Insufficient compression
• Variable valve timing control system improper operation
• Purge solenoid valve malfunction
• PCV valve malfunction
• Related connector and terminal malfunction
• Related wiring harness malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
4 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the suspected circuit or part or both according to
(KEY TO ON/IDLE) inspection results.
• Access APP1, APP2, APP3, ECT, IAT, MAF, (See 01-40-5 PCM INSPECTION [MZI-3.5].)
RPM, TP_REL and VSS PIDs using the M- Then go to Step 18.
MDS. No Go to the next step.
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
• Is there any signal that is far out of specification
when the ignition switch is in the ON position
and engine runs at idle?
5 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the suspected circuit or part or both according to
UNDER TROUBLE CONDITION inspection results.
• Inspect the same PIDs as in Step 4 when (See 01-40-5 PCM INSPECTION [MZI-3.5].)
simulating the FREEZE FRAME DATA Then go to Step 18.
condition. No Go to the next step.
• Is there any signal which causes drastic
changes?

01-02–94
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
6 INSPECT CMP SENSOR Yes Inspect the installation condition for damage to the timing
• Inspect the CMP sensor. belt and gears, and repair malfunctioning parts.
(See 01-40-18 CAMSHAFT POSITION (CMP) • If it is normal, replace CMP sensor.
SENSOR INSPECTION [MZI-3.5].) (See 01-40-18 CAMSHAFT POSITION (CMP)
• Is there any malfunction? SENSOR REMOVAL/INSTALLATION [MZI-3.5].)
Then go to Step 18.
No Go to the next step. 01-02
7 VERIFY CKP SENSOR INSTALLATION Yes Retighten the CKP sensor, then go to Step 18.
CONDITION (See 01-40-16 CRANKSHAFT POSITION (CKP) SENSOR
• Inspect for CKP sensor looseness. REMOVAL/INSTALLATION [MZI-3.5].)
• Is the CKP sensor loose? No Go to the next step.
8 INSPECT IGNITION SYSTEM OPERATION Yes Go to the next step.
• Perform the spark test. No Repair or replace the malfunctioning part according to the
(See 01-03-60 ENGINE CONTROL SYSTEM spark test results, then go to Step 18.
OPERATION INSPECTION [MZI-3.5].)
• Are the results of the spark test normal?
9 INSPECT MAF PID Yes Go to the next step.
• Start the engine. No Replace the MAF/IAT sensor, then go to Step 18.
• Access the MAF PID using the M-MDS. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
• Verify that the MAF PID changes quickly INSTALLATION [MZI-3.5].)
according to the engine speed when the
engine is raced.
• Is the MAF PID response normal?
10 INSPECT FOR EXCESSIVE AIR SUCTION IN Yes Repair or replace the suspected part, then go to Step 18.
INTAKE AIR SYSTEM No Go to the next step.
• Inspect for air leakage at the following:
— Between the MAF/IAT sensor and the
throttle body
— Between the throttle body and the dynamic
chamber
• Is there any malfunction?
11 INSPECT FUEL LINE PRESSURE Yes If the fuel line pressure is too low, go to the next step. If the
• Turn the ignition switch off. fuel line pressure is excessively high, check as follows:
• Inspect the fuel line pressure. • Fuel pump maximum pressure
(See 01-14-6 FUEL LINE PRESSURE • Fuel return line for clogging
INSPECTION [MZI-3.5].) — If all of the above are normal, replace the pressure
• Is there any malfunction? regulator.
(See 01-14-27 PRESSURE REGULATOR
INSPECTION [MZI-3.5].)
Then go to Step 18.
No Go to Step 18.
12 INSPECT FUEL LINE FROM FUEL PUMP TO Yes Replace suspected fuel line, then go to Step 18.
FUEL DELIVERY PIPE No Inspect the low-pressure side fuel filter for the following:
• Visually inspect the fuel line for any leakage. • Foreign material or staining inside the fuel filter
• Is any fuel leakage found? Perform the following actions as a result:
• If foreign material or staining is found inside the fuel
filter (low-pressure side), clean the fuel tank and filter.
• If normal, replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
Then, go to Step 18.
13 INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect the engine compression. No Perform an engine overhaul for repairs, then go to Step 18.
(See 01-10-9 COMPRESSION INSPECTION
[MZI-3.5].)
• Is it normal?
14 INSPECT VARIABLE VALVE TIMING CONTROL Yes Go to the next step.
SYSTEM OPERATION No Repair or replace the malfunctioning part according to the
• Inspect the variable valve timing control system variable valve timing control system inspection results, then
operation. go to Step 18.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
• Does the variable timing control system work
properly?

01-02–95
1890-1U-06H(01-02).fm 96 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
15 INSPECT OPERATION OF PURGE SOLENOID Yes Go to the next step.
VALVE No Repair or replace the malfunctioning part according to the
• Inspect the purge control system operation. purge control system inspection results, then go to Step 18.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
• Does the purge control system work properly?
16 INSPECT PCV VALVE OPERATION Yes Replace the PCV valve, then go to Step 18.
• Turn the ignition switch off. No Go to the next step.
• Remove the PCV valve and check the valve
operation.
(See 01-16-10 POSITIVE CRANKCASE
VENTILATION (PCV) VALVE INSPECTION
[MZI-3.5].)
• Is the PCV valve operation normal?
17 INSPECT SEALING OF ENGINE COOLANT Yes Air penetrates due to poor sealing of the head gasket or
PASSAGE other areas between the combustion chamber and the
engine coolant passage. Repair or replace malfunctioning
Warning parts, then go to the next step.
• Never remove the cooling system cap or No Go to the next step.
loosen the radiator drain plug while the
engine is running, or when the engine
and radiator are hot. Scalding engine
coolant and steam may shoot out and
cause serious injury. It may also damage
the engine and cooling system.
• Turn off the engine and wait until it is
cool. Even then, be very careful when
removing the cap. Wrap a thick cloth
around it and slowly turn it
counterclockwise to the first stop. Step
back while the pressure escapes
• When you are sure all the pressure is
gone, press down on the cap using the
cloth, turn it, and remove it.

• Remove the radiator cap.

• Implement the procedure to bleed air from the
engine coolant, then run the engine at idle
• Are there any small bubbles which make the
engine coolant white at the filling opening?

Note
• Large bubbles are normal since they are
remaining air coming from the engine
coolant passage.
18 VERIFY TROUBLESHOOTING OF DTC P0300 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOER SELF TEST using the M-
MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for this DTC present?
19 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
WM: DTC P03XX

01-02–96
1890-1U-06H(01-02).fm 97 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0301, P0302, P0303, P0304, P0305, P0306, P0316 [MZI-3.5]
id0102d1880800

DTC P0301P0301: Cylinder No.1 misfire detected

DTC P0302P0302: Cylinder No.2 misfire detected
DTC P0303P0303: Cylinder No.3 misfire detected
DTC P0304P0304: Cylinder No.4 misfire detected
DTC P0305P0305: Cylinder No.5 misfire detected
DTC P0306P0306: Cylinder No.6 misfire detected
DTC P0316P0316:Misfire detected on startup (first 1000 revolutions) 01-02
• The PCM monitors the crankshaft position sensor input signal interval time. The PCM calculates the
change of the interval time for each cylinder. If the change of interval time exceeds the pre-programmed
criteria, the PCM detects a misfire in the corresponding cylinder. when the engine is running, the PCM
DETECTION
counts the number of misfires that occurred at 200 crankshaft revolutions and 1,000 crankshaft revolutions
CONDITION
and calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the pre-programmed
criteria, the PCM determines that a misfire, which can damage the catalytic converter or affect emission
performance, has occurred.
• Spark plug malfunction
• Ignition system malfunction
• Ignition coil malfunction
POSSIBLE • Fuel injector malfunction
CAUSE • Air suction in intake air system (between dynamic chamber and cylinder head)
• Inadequate engine compression due to engine internal malfunction
• Related connector or terminal malfunction
• Related wiring harness malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
4 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the suspected circuit or part or both according to
(KEY TO ON /IDLE) inspection results. Then go to Step 13.
• Access APP1, APP2, APP3, ECT, IAT, MAF, (See 01-40-5 PCM INSPECTION [MZI-3.5].)
RPM TP_REL and VSS PIDs using the M- No Go to the next step.
MDS.
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
• Is there any signal that is far out of specification
when the ignition switch is in the ON position
and the engine runs at idle?
5 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the suspected circuit or part or both according
UNDER TROUBLE CONDITION inspection results. Then go to Step 13.
• Inspect the same PIDs as in Step 4 when (See 01-40-5 PCM INSPECTION [MZI-3.5].)
simulating the FREEZE FRAME DATA No Go to the next step.
condition.
• Is there any signal which causes drastic
changes?
6 INSPECT SPARK PLUG CONDITION Yes • If the spark plug is wet, fuel flooding is suspected. Go to
• Turn the ignition switch off. Step 9.
• Remove the spark plug from the suspected • If the spark plug has a crack, excess wear or improper
cylinder. gap, replace the malfunctioning spark plug. Then go to
• Check the spark plug condition: Step 13.
— Cracks (See 01-18-3 SPARK PLUG REMOVAL/INSTALLATION
— Excess wear [MZI-3.5].)
— Gap No Go to the next step.
— Wet
• Is any problem found on the spark plug?

01-02–97
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
7 INSPECT IGNITION SYSTEM OPERATION FOR Yes Go to the next step.
SUSPECTED CYLINDER No Replace or replace the malfunctioning part according to the
• Perform the spark test for the suspected spark test results, then go to Step 13.
cylinder.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
• Are the results of the spark test normal?
8 INSPECT FUEL INJECTOR WIRING HARNESS Yes Go to the next step.
• Remove the intake air system parts. No Inspect the fuel injector wiring harnesses. Repair or replace
• Disconnect the fuel injector connector on the if necessary, then go to Step 13.
suspected cylinder.
• Connect the noid light to the fuel injector
connector terminals.
• Verify the light dimness during cranking.
• Does the noid light illuminate?
9 INSPECT FUEL INJECTOR OPERATION Yes Replace fuel injector, then go to Step 13.
• Remove fuel injector from the suspected (See 01-14-23 FUEL INJECTOR REMOVAL/
cylinder. INSTALLATION [MZI-3.5].)
(See 01-14-23 FUEL INJECTOR REMOVAL/ No Go to the next step.
INSTALLATION [MZI-3.5].)
• Swap the fuel injector with one from another
cylinder.
• Start the engine and run it at idle.
• Is there the misfire DTC for the cylinder which
has a suspected fuel injector?
10 INSPECT FOR AIR SUCTION AT INTAKE AIR Yes Repair or replace the suspected part, then go to Step 13.
SYSTEM No Go to the next step.
• Inspect for air leakage at the following:
— Around the connection of the dynamic
chamber and the intake manifold
— Around the connection of the intake
manifold and the cylinder head
• Is air leakage found?
11 INSPECT SEALING OF ENGINE COOLANT Yes Air penetrates due to poor sealing of the head gasket or
PASSAGE other areas between the combustion chamber and the
engine coolant passage. Repair or replace malfunctioning
Warning parts, then go to Step 13.
• Never remove the cooling system cap or No Go to the next step.
loosen the radiator drain plug while the
engine is running, or when the engine
and radiator are hot. Scalding engine
coolant and steam may shoot out and
cause serious injury. It may also damage
the engine and cooling system.
• Turn off the engine and wait until it is
cool. Even then, be very careful when
removing the cap. Wrap a thick cloth
around it and slowly turn it
counterclockwise to the first stop. Step
back while the pressure escapes.
• When you are sure all the pressure is
gone, press down on the cap using the
cloth, turn it, and remove it.

• Remove the radiator cap.

• Implement the procedure to bleed air from the
engine coolant, then run the engine at idle.
• Are there any small bubbles which make the
engine coolant white at filling opening?

Note
• Large bubbles are normal since they are
remaining air coming from the engine
coolant passage.

01-02–98
1890-1U-06H(01-02).fm 99 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
12 INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect the engine compression. No Overhaul the engine, then go to the next step.
(See 01-10-9 COMPRESSION INSPECTION
[MZI-3.5].)
• Is the engine compression normal?
13 VERIFY TROUBLESHOOTING OF MISFIRE DTC Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].) 01-02
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
14 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–99
1890-1U-06H(01-02).fm 100 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0315 [MZI-3.5]
id0102d1820200

DTC P0315 CKP system variation not learned

DETECTION • The PCM is unable to learn and correct for mechanical inaccuracies in the crankshaft pulse wheel tooth
CONDITION spacing. This DTC disables the misfire monitor.
POSSIBLE • Crankshaft pulse wheel teeth malfunction
CAUSE • CKP sensor malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
4 INSPECT PHYSICAL CONDITION OF Yes Go to the next step.
CRANKSHAFT PULSE WHEEL No Repair if necessary. Then go to Step 6.

Note
• DTC P0315 is set when the PCM is unable
to learn and correct for the mechanical
variations in the crankshaft pulse wheel
tooth spacing (the allowable correction
tolerances are exceeded).

• Inspect the crankshaft pulse wheel for

damaged teeth.
• Inspect the crankshaft pulse wheel for wobble.
• Check for a loose crankshaft pulse wheel.
• Check the CKP sensor for damage.
• Are the CKP sensor and crankshaft pulse
wheel normal?
5 INSPECT DAMPER AND PULLEY ASSEMBLY Yes Disconnect the negative battery terminal for 5 min to allow
the PCM to learn the new profile. Install a new pulley or
Note damper assembly. Then go to the next step.
• This step is for engines that have damper No Go to the next step.
mounted pulse rings. Remove the front
cover if necessary to observe the crank
pulley.

• Observe the crank pulley for wobble.

• Examine the EI pulse ring fastened to the
harmonic dampener.
• Does the crank pulley wobble or is the pulse
ring loose or damaged?
6 VERIFY TROUBLESHOOTING OF DTC P0315 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?

01-02–100
1890-1U-06H(01-02).fm 101 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie 01-02

DTC P0320 [MZI-3.5]
id0102d1820300

DTC P0320 Ignition/distributor engine speed input circuit

DETECTION • The ignition engine speed sensor input signal to the PCM is continuously monitored.
CONDITION • The test fails when the signal indicates that 2 successive erratic PIP pulses occurred.
• Loose wires/connectors.
POSSIBLE
• Arcing secondary ignition components (coil, wires or plugs).
CAUSE
• On-board transmitter (2-way radio).
CKP SENSOR PCM

7 6 9 10 11 12
A 2P CKP SENSOR (+)

6 9 10 11 12
B 2T CKP SENSOR (-)

PCM
CKP SENSOR
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
B A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?

01-02–101
1890-1U-06H(01-02).fm 102 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT CKP SENSOR SIGNAL SENT TO PCM Yes Go to Step 13.
No Go to the next step.
Note
• The battery should be fully charged and the
starting system should be functioning
properly.

• Disable the inertia switch.

• Perform the KOEO self-test.
• Access the PCM and monitor the RPM PID.
• Crank the engine.
• Is the engine speed more than 150 rpm?
5 INSPECT TIMING COVER, CKP SENSOR AND Yes Repair if necessary. Then go to Step 13.
EXTERNAL TRIGGER WHEEL (OUTSIDE No Go to Step.
TIMING COVER) FOR OBVIOUS PHYSICAL
DAMAGE
• Visually check the timing cover, CKP sensor
and external trigger wheel (outside the timing
cover) for obvious physical damage.
• Do any parts appear physically damaged?
6 INSPECT FOR PROPER CKP BIAS VOLTAGES Yes Go to the next step.
IN PCM No Go to Step 8.
• Disconnect the CKP sensor connector.
• Perform the KOEO self-test.
• Measure the voltage between:
— CKP sensor terminal A on the wiring
harness side and battery negative
— CKP sensor terminal B on the wiring
harness side and battery negative
• Are the voltages between 1—3 V?
7 INSPECT CKP SENSOR RESISTANCE Yes Go to the next step.
• Turn the ignition switch off. No Replace the CKP sensor. Then go to Step 13.
• Measure the resistance between CKP sensor
terminal A and B on the component side.
• Is the resistance between 0.25—1 kilohms?
8 INSPECT CKP WIRING HARNESS SHIELD Yes Go to the next step.
CIRCUIT FOR SHORT TO GROUND No Repair the short circuit. Check for a poor ground. Then go
to Step 13.
Note
• The wiring harness shield protects the CKP
signal from electrical noise and is grounded
at one end, typically near the PCM.

Note
• Perform the following resistance
measurement between the CKP shield and
the ground.

• Measure the resistance between:

— CKP_SHLD assembly connector wiring
harness side and ground
• Is the resistance less than 5 ohms?
9 INSPECT FOR SHORT BETWEEN CKP (+) AND Yes Go to the next step.
CKP (-) IN WIRING HARNESS No Repair or replace suspected part, Then go to Step 13.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Measure the resistance between:
— CKP sensor terminal A and B on the wiring
harness side
• Is the resistance more than 10 kilohms?

01-02–102
1890-1U-06H(01-02).fm 103 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
10 INSPECT CKP CIRCUIT(S) FOR OPEN CIRCUIT Yes Go to the next step.
IN WIRING HARNESS No Repair or replace suspected part, Then go to Step 13.
• Measure the resistance between:
— CKP sensor connector A on the wiring
harness side and PCM terminal 2P
— CKP sensor connector B on the wiring
harness side and PCM terminal 2T 01-02
• Are the resistances less than 5 ohms?
11 INSPECT CKP CIRCUIT(S) FOR SHORT TO Yes Go to the next step.
GROUND IN WIRING HARNESS No Repair or replace suspected part, Then go to Step 13.
• Measure the resistance between:
— CKP sensor connector A on the wiring
harness side and battery negative
— CKP sensor connector B on the wiring
harness side and battery negative
• Are the resistances more than 10 kilohms?
12 INSPECT CKP CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, Then go to Step 13.
VOLTAGE IN WIRING HARNESS No Go to the next step.
• Perform the KOEO self-test.
• Measure the voltage between:
— CKP sensor connector A on the wiring
harness side and battery negative
— CKP sensor connector B on the wiring
harness side and battery negative
• Are any voltage present?
13 VERIFY TROUBLESHOOTING OF DTC P0320 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
14 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
SOKYU_WM: DTC P03XX

01-02–103
1890-1U-06H(01-02).fm 104 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0325 [MZI-3.5]
id0102d1873300

DTC P0325 KS circuit (RH)

DETECTION • The KS detects vibrations upon increase and decrease in engine RPM. The KS generates a voltage based
CONDITION on this vibration. A DTC is set if the voltage goes outside a calibrated level.
• Open circuit wiring harness between KS terminal C and PCM terminal 2L
• Short to power supply in wiring harness between KS terminal C and PCM terminal 2L
• Short to ground circuit between KS terminal C and PCM terminal 2L
POSSIBLE • Open circuit wiring harness between KS terminal D and PCM terminal 2G
CAUSE • Short to power supply in wiring harness between KS terminal D and PCM terminal 2G
• Short to ground circuit between KS terminal D and PCM terminal 2G
• Connector or terminal malfunction
• KS malfunction
KS (RH) PCM
(KS)

8
3 4 5 7 6
D 2G KS (RH) (+)

3 4 5 7 6
C 2L KS (RH) (-)

PCM
WIRING HARNESS-SIDE CONNECTOR
KS
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

A B C D
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT KS CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the KS connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–104
1890-1U-06H(01-02).fm 105 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT KS (RH) SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 9.
SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals:
— KS terminal C and body ground. 01-02
— KS terminal D and body ground.
• Are the voltage B+?
5 INSPECT KS (RH) CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to Step 9.
GROUND No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect for continuity between the following
terminals:
— KS terminal C and body ground.
— KS terminal D and body ground.
• Are there continuity?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
7 INSPECT KS (RH) CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Turn the ignition switch off.
• Inspect for continuity between the following
terminals:
— KS terminal C and PCM terminal 2L
— KS terminal D and PCM terminal 2G
• Is there continuity?
8 INSPECT THE KS (RH) Yes Replace the KS, then go to the next step. (See 01-40-26
• Inspect the KS (RH). KNOCK SENSOR (KS) REMOVAL/INSTALLATION [MZI-
(See 01-40-27 KNOCK SENSOR (KS) 3.5].)
INSPECTION [MZI-3.5].) No Go to the next step.
• Is there malfunction?
9 VERIFY TROUBLESHOOTING OF DTC P0325 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–105
1890-1U-06H(01-02).fm 106 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0330 [MZI-3.5]
id0102d1807200

DTC P0330 KS circuit (LH)

DETECTION • The KS detects vibrations upon increase and decrease in engine RPM. The KS generates a voltage based
CONDITION on this vibration. A DTC is set if the voltage goes outside a calibrated level.
• Open circuit wiring harness between KS terminal A and PCM terminal 2Q
• Short to power supply in wiring harness between KS terminal A and PCM terminal 2Q
• Short to ground circuit between KS terminal A and PCM terminal 2Q
POSSIBLE • Open circuit wiring harness between KS terminal B and PCM terminal 2M
CAUSE • Short to power supply in wiring harness between KS terminal B and PCM terminal 2M
• Short to ground circuit between KS terminal B and PCM terminal 2M
• Connector or terminal malfunction
• KS malfunction

KS (LH) PCM
(KS)

3 4 5 7 6
B 2M KS (LH) (+)

8
3 4 5 7 6
A 2Q KS (LH) (-)

PCM
WIRING HARNESS-SIDE CONNECTOR
KS
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

A B C D
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT KS CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the KS connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–106
1890-1U-06H(01-02).fm 107 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT KS (LH) SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 9.
SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals:
— KS terminal A and body ground. 01-02
— KS terminal B and body ground.
• Are there voltage B+?
5 INSPECT KS (LH) CIRCUIT FOR SHORT TO Yes Repair or replace suspected part, then go to Step 9.
GROUND No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect for continuity between the following
terminals:
— KS terminal A and body ground.
— KS terminal B and body ground.
• Are there continuity?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
7 INSPECT KS (LH) CIRCUIT FOR OPEN CIRCUIT Yes Go to the next step.
• Turn the ignition switch off. No Repair or replace suspected part, then go to Step 9.
• Inspect for continuity between the following
terminals:
— KS terminal A and PCM terminal 2Q
— KS terminal B and PCM terminal 2M
• Are there continuity?
8 INSPECT THE KS (LH) Yes Replace the KS, then go to the next step.(See 01-40-26
• Inspect the KS (LH). KNOCK SENSOR (KS) REMOVAL/INSTALLATION [MZI-
(See 01-40-27 KNOCK SENSOR (KS) 3.5].)
INSPECTION [MZI-3.5].) No Go to the next step.
• Is there malfunction?
9 VERIFY TROUBLESHOOTING OF DTC P0330 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–107
1890-1U-06H(01-02).fm 108 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0340 [MZI-3.5]
id0102d1807000

DTC P0340 CMP sensor (RH) circuit

DETECTION
• The test fails when the PCM can no longer detect the signal from the CMP sensor (RH).
CONDITION
• Connector or terminal malfunction
• CMP sensor (RH) malfunction
• Short to ground circuit between CMP sensor (RH) terminal A and PCM terminal 2X
POSSIBLE
• Short to power supply between CMP sensor (RH) terminal A and PCM terminal 2X
CAUSE
• Open circuit between CMP sensor (RH) terminal A and PCM terminal 2X
• Open circuit between CMP sensor (RH) terminal B and PCM terminal 2C
• PCM malfunction

CMP SENSOR (RH) PCM

53 6 7 9 8
A 2X

10

5 9 8
B 2C

PCM
WIRING HARNESS-SIDE CONNECTOR

CMP SENSOR (RH)

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

B A
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–108
1890-1U-06H(01-02).fm 109 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 CLEAR AND ATTEMPT TO RETRIEVE THE DTC Yes Go to the next step.
No Perform the “INTERMITTENT CONCERN
Note TROUBLESHOOTING”. Then go to Step 11.
• If DTCs P0340, P0344, P0345 or P0349 are
present, ignition, alternator noise, radio
frequency interference and CKP concerns
should be considered. 01-02
• Clear the DTC from the PCM memory using
the M-MDS.
• Turn the ignition switch to the ON position
(Engine running).
• Increase engine speed to more than 1,500
rpm for 10 s. Repeat this 3 times.
• Retrieve the continuous memory DTCs.
• The same DTC present?
4 CHECK THE GENERATOR FOR EXCESSIVE Yes Go to the next step.
ELECTRICAL NOISE No • Inspect the charging system, then go to Step 11.
— Drive belt damaged and misinstallation
Note — Generator pulley or generator misinstallation
• If the generator/regulator is electrically
noisy, the noise decreases when the
terminal B is disconnected.

• Turn the ignition switch to the ON position

(Engine running).
• Monitor the generator for an audible electric
noise.
• Turn the ignition switch off.
• Generator/regulator terminal B disconnected.
• Turn the ignition switch to the ON position
(Engine running).
• With the engine running, determine if the
generator is still noisy.
• Does the noise remain constant when the
terminal B is disconnected?
5 INSPECT CMP SENSOR (RH) CONNECTOR Yes Repair or replace suspected part, then go to Step 11.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the CMP sensor (RH) connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT CMP SENSOR SIGANAL CIRCUIT Yes Repair or replace suspected part, then go to Step 11.
FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between CMP sensor (RH)
terminal A (wiring harness-side) and body
ground.
• Is the voltage B+?
7 INSPECT CMP SENSOR (RH) SIGNAL CIRCUIT Yes Repair or replace suspected part, then go to Step 11.
FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Check continuity between CMP sensor (RH)
terminal A and body ground.
• Is there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 11.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Check for poor connection (such as damaged,
pulled-out pins, and corrosion).
• Are there any malfunction?

01-02–109
1890-1U-06H(01-02).fm 110 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 INSPECT CMP SENSOR (RH) CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 11.
• Turn the ignition switch off.
• Check continuity between the following circuits:
— CMP sensor (RH) terminal A and PCM
terminal 2X
— CMP sensor (RH) terminal B and PCM
terminal 2C
• Is there continuity?
10 INSPECT CMP SENSOR (RH) Yes Replace CMP sensor (RH), then go to the next step.
• Inspect CMP sensor (RH). (See 01-40-18 CAMSHAFT POSITION (CMP) SENSOR
(See 01-40-18 CAMSHAFT POSITION (CMP) REMOVAL/INSTALLATION [MZI-3.5].)
SENSOR INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
11 VERIFY TROUBLESHOOTING OF DTC P0340 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Access the MAF PID using the M-MDS.
• Is same DTC present?
12 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
WM: DTC P03XX

01-02–110
1890-1U-06H(01-02).fm 111 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0344 [MZI-3.5]
id0102d1831300

DTC P0344 CMP sensor (RH) circuit intermittent

DETECTION
• The test fails when the PCM detects an intermittent signal from the CMP sensor.
CONDITION
• Connector or terminal malfunction
• CMP sensor (RH) malfunction
• Sensor shielding malfunction 01-02
POSSIBLE
• Short to ground circuit between CMP sensor (RH) terminal A and PCM terminal 2X
CAUSE
• Short to power supply between CMP sensor (RH) terminal A and PCM terminal 2X
• Open circuit between CMP sensor (RH) terminal A and PCM terminal 2X
• Open circuit between CMP sensor (RH) terminal B and PCM terminal 2C
CMP SENSOR (RH) PCM

53 6 7 9 8
A 2X

10

5 9 8
B 2C

PCM
WIRING HARNESS-SIDE CONNECTOR

CMP SENSOR (RH)

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

B A
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–111
1890-1U-06H(01-02).fm 112 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 CLEAR AND ATTEMPT TO RETRIEVE THE DTC Yes Go to the next step.
No Perform the “INTERMITTENT CONCERN
Note TROUBLESHOOTING”. Then go to Step 11.
• If DTCs P0340, P0344, P0345 or P0349 are
present, ignition, alternator noise, radio
frequency interference and CKP concerns
should be considered.

• Clear the DTC from the PCM memory using

the M-MDS.
• Turn the ignition switch to the ON position
(Engine running).
• Increase engine speed to more than 1,500
rpm for 10 s. Repeat this 3 times.
• Retrieve the continuous memory DTCs.
• The same DTC present?
4 CHECK THE GENERATOR FOR EXCESSIVE Yes Go to the next step.
ELECTRICAL NOISE No • Inspect the charging system, then go to Step 11.
— Drive belt damaged and misinstallation
Note — Generator pulley or generator misinstallation
• If the generator/regulator is electrically
noisy, the noise decreases when the
terminal B is disconnected.

• Turn the ignition switch to the ON position

(Engine running).
• Monitor the generator for an audible electric
noise.
• Turn the ignition switch off.
• Generator/regulator terminal B disconnected.
• Turn the ignition switch to the ON position
(Engine running).
• With the engine running, determine if the
generator is still noisy.
• Does the noise remain constant when the
terminal B is disconnected?
5 INSPECT CMP SENSOR (RH) CONNECTOR Yes Repair or replace suspected part, then go to Step 11.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the CMP sensor (RH) connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT CMP SENSOR SIGANAL CIRCUIT Yes Repair or replace suspected part, then go to Step 11.
FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between CMP sensor (RH)
terminal A (wiring harness-side) and body
ground.
• Is the voltage B+?
7 INSPECT CMP SENSOR (RH) SIGNAL CIRCUIT Yes Repair or replace suspected part, then go to Step 11.
FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Check continuity between CMP sensor (RH)
terminal A and body ground.
• Is there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 11.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Check for poor connection (such as damaged,
pulled-out pins, and corrosion).
• Are there any malfunction?

01-02–112
1890-1U-06H(01-02).fm 113 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 INSPECT CMP SENSOR (RH) CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 11.
• Turn the ignition switch off.
• Check continuity between the following circuits:
— CMP sensor (RH) terminal A and PCM
terminal 2X
— CMP sensor (RH) terminal B and PCM 01-02
terminal 2C
• Is there continuity?
10 INSPECT CMP SENSOR (RH) Yes Replace CMP sensor (RH), then go to the next step.
• Inspect CMP sensor (RH). (See 01-40-18 CAMSHAFT POSITION (CMP) SENSOR
(See 01-40-18 CAMSHAFT POSITION (CMP) REMOVAL/INSTALLATION [MZI-3.5].)
SENSOR INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
11 VERIFY TROUBLESHOOTING OF DTC P0344 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Access the MAF PID using the M-MDS.
• Is same DTC present?
12 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–113
1890-1U-06H(01-02).fm 114 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0345 [MZI-3.5]
id0102d1952000

DTC P0345 CMP sensor (LH) circuit

DETECTION
• The test fails when the PCM can no longer detect the signal from the CMP sensor (LH).
CONDITION
• Connector or terminal malfunction
• CMP sensor (LH) malfunction
• Short to ground circuit between CMP sensor (LH) terminal A and PCM terminal 2AB
POSSIBLE
• Short to power supply between CMP sensor (LH) terminal A and PCM terminal 2AB
CAUSE
• Open circuit between CMP sensor (LH) terminal A and PCM terminal 2AB
• Open circuit between CMP sensor (LH) terminal B and PCM terminal 2C
• PCM malfunction
CMP SENSOR (LH) PCM

53 6 7 9 8
A 2AB

10

5 9 8
B 2C

PCM
WIRING HARNESS-SIDE CONNECTOR

CMP SENSOR (LH)

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

B A
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–114
1890-1U-06H(01-02).fm 115 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 CLEAR AND ATTEMPT TO RETRIEVE THE DTC Yes Go to the next step.
No Perform the “INTERMITTENT CONCERN
Note TROUBLESHOOTING”. Then go to Step 11.
• If DTCs P0340, P0344, P0345 or P0349 are
present, ignition, alternator noise, radio
frequency interference and CKP concerns
should be considered. 01-02
• Clear the DTC from the PCM memory using
the M-MDS.
• Turn the ignition switch to the ON position
(Engine running).
• Increase engine speed to more than 1,500
rpm for 10 s. Repeat this 3 times.
• Retrieve the continuous memory DTCs.
• The same DTC present?
4 CHECK THE GENERATOR FOR EXCESSIVE Yes Go to the next step.
ELECTRICAL NOISE No • Inspect the charging system, then go to Step 11.
— Drive belt damaged and misinstallation
Note — Generator pulley or generator misinstallation
• If the generator/regulator is electrically
noisy, the noise decreases when the
terminal B is disconnected.

• Turn the ignition switch to the ON position

(Engine running).
• Monitor the generator for an audible electric
noise.
• Turn the ignition switch off.
• Generator/regulator terminal B disconnected.
• Turn the ignition switch to the ON position
(Engine running).
• With the engine running, determine if the
generator is still noisy.
• Does the noise remain constant when the
terminal B is disconnected?
5 INSPECT CMP SENSOR (LH) CONNECTOR Yes Repair or replace suspected part, then go to Step 11.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the CMP sensor (LH) connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT CMP SENSOR SIGANAL CIRCUIT Yes Repair or replace suspected part, then go to Step 11.
FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between CMP sensor (LH)
terminal A (wiring harness-side) and body
ground.
• Is the voltage B+?
7 INSPECT CMP SENSOR (LH) SIGNAL CIRCUIT Yes Repair or replace suspected part, then go to Step 11.
FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Check continuity between CMP sensor (LH)
terminal A and body ground.
• Is there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 11.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Check for poor connection (such as damaged,
pulled-out pins, and corrosion).
• Are there any malfunction?

01-02–115
1890-1U-06H(01-02).fm 116 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 INSPECT CMP SENSOR (LH) CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 11.
• Turn the ignition switch off.
• Check continuity between the following circuits:
— CMP sensor (LH) terminal A and PCM
terminal 2AB
— CMP sensor (LH) terminal B and PCM
terminal 2C
• Is there continuity?
10 INSPECT CMP SENSOR (LH) Yes Replace CMP sensor (LH), then go to the next step.
• Inspect CMP sensor (LH). (See 01-40-18 CAMSHAFT POSITION (CMP) SENSOR
(See 01-40-18 CAMSHAFT POSITION (CMP) REMOVAL/INSTALLATION [MZI-3.5].)
SENSOR INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
11 VERIFY TROUBLESHOOTING OF DTC P0345 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Access the MAF PID using the M-MDS.
• Is same DTC present?
12 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–116
1890-1U-06H(01-02).fm 117 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0349 [MZI-3.5]
id0102d1873400

DTC P0349 CMP sensor (LH) circuit intermittent

DETECTION
• The test fails when the PCM detects an intermittent signal from the CMP sensor (LH).
CONDITION
• Connector or terminal malfunction
• CMP sensor (LH) malfunction
• Sensor shielding malfunction 01-02
POSSIBLE
• Short to ground circuit between CMP sensor (LH) terminal A and PCM terminal 2AB
CAUSE
• Short to power supply between CMP sensor (LH) terminal A and PCM terminal 2AB
• Open circuit between CMP sensor (LH) terminal A and PCM terminal 2AB
• Open circuit between CMP sensor (LH) terminal B and PCM terminal 2C
CMP SENSOR (LH) PCM

53 6 7 9 8
A 2AB

10

5 9 8
B 2C

PCM
WIRING HARNESS-SIDE CONNECTOR

CMP SENSOR (LH)

WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

B A
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–117
1890-1U-06H(01-02).fm 118 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 CLEAR AND ATTEMPT TO RETRIEVE THE DTC Yes Go to the next step.
No Perform the “INTERMITTENT CONCERN
Note TROUBLESHOOTING”. Then go to Step 11.
• If DTCs P0340, P0344, P0345 or P0349 are
present, ignition, alternator noise, radio
frequency interference and CKP concerns
should be considered.

• Clear the DTC from the PCM memory using

the M-MDS.
• Turn the ignition switch to the ON position
(Engine running).
• Increase engine speed to more than 1,500
rpm for 10 s. Repeat this 3 times.
• Retrieve the continuous memory DTCs.
• The same DTC present?
4 CHECK THE GENERATOR FOR EXCESSIVE Yes Go to the next step.
ELECTRICAL NOISE No • Inspect the charging system, then go to Step 11.
— Drive belt damaged and misinstallation
Note — Generator pulley or generator misinstallation
• If the generator/regulator is electrically
noisy, the noise decreases when the
terminal B is disconnected.

• Turn the ignition switch to the ON position

(Engine running).
• Monitor the generator for an audible electric
noise.
• Turn the ignition switch off.
• Generator/regulator terminal B disconnected.
• Turn the ignition switch to the ON position
(Engine running).
• With the engine running, determine if the
generator is still noisy.
• Does the noise remain constant when the
terminal B is disconnected?
5 INSPECT CMP SENSOR (LH) CONNECTOR Yes Repair or replace suspected part, then go to Step 11.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the CMP sensor (LH) connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT CMP SENSOR SIGANAL CIRCUIT Yes Repair or replace suspected part, then go to Step 11.
FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between CMP sensor (LH)
terminal A (wiring harness-side) and body
ground.
• Is the voltage B+?
7 INSPECT CMP SENSOR (LH) SIGNAL CIRCUIT Yes Repair or replace suspected part, then go to Step 11.
FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Check continuity between CMP sensor (LH)
terminal A and body ground.
• Is there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 11.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Check for poor connection (such as damaged,
pulled-out pins, and corrosion).
• Are there any malfunction?

01-02–118
1890-1U-06H(01-02).fm 119 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 INSPECT CMP SENSOR (LH) CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 11.
• Turn the ignition switch off.
• Check continuity between the following circuits:
— CMP sensor (LH) terminal A and PCM
terminal 2AB
— CMP sensor (LH) terminal B and PCM 01-02
terminal 2C
• Is there continuity?
10 INSPECT CMP SENSOR (LH) Yes Replace CMP sensor (LH), then go to the next step.
• Inspect CMP sensor (LH). (See 01-40-18 CAMSHAFT POSITION (CMP) SENSOR
(See 01-40-18 CAMSHAFT POSITION (CMP) REMOVAL/INSTALLATION [MZI-3.5].)
SENSOR INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
11 VERIFY TROUBLESHOOTING OF DTC P0349 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Access the MAF PID using the M-MDS.
• Is same DTC present?
12 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P0351, 0352, 0353, 0354, 0355, 0356 [MZI-3.5]
id0102d1873500

DTC P0351 P0351: Ignition coil No.1 primary/secondary circuit

DTC P0352 P0352: Ignition coil No.2 primary/secondary circuit
DTC P0353 P0353: Ignition coil No.3 primary/secondary circuit
DTC P0354 P0354: Ignition coil No.4 primary/secondary circuit
DTC P0355 P0355: Ignition coil No.5 primary/secondary circuit
DTC P0356 P0356: Ignition coil No.6 primary/secondary circuit
DETECTION • Each ignition primary circuit is continuously monitored. The test fails when the PCM does not receive a
CONDITION valid ignition diagnostic monitor pulse signal from the ignition module (integrated in the PCM).
• Connector or terminal malfunction
• Open circuit between ignition coil No.1 terminal C and PCM terminal 2A
• Open circuit between ignition coil No.2 terminal C and PCM terminal 2F
• Open circuit between ignition coil No.3 terminal C and PCM terminal 2K
• Open circuit between ignition coil No.4 terminal C and PCM terminal 2W
• Open circuit between ignition coil No.5 terminal C and PCM terminal 2AA
• Open circuit between ignition coil No.6 terminal C and PCM terminal 2AE
• Short to power supply between ignition coil No.1 terminal C and PCM terminal 2A
• Short to power supply between ignition coil No.2 terminal C and PCM terminal 2F
• Short to power supply between ignition coil No.3 terminal C and PCM terminal 2K
POSSIBLE
• Short to power supply between ignition coil No.4 terminal C and PCM terminal 2W
CAUSE
• Short to power supply between ignition coil No.5 terminal C and PCM terminal 2AA
• Short to power supply between ignition coil No.6 terminal C and PCM terminal 2AE
• Short to ground circuit between ignition coil No.1 terminal C and PCM terminal 2A
• Short to ground circuit between ignition coil No.2 terminal C and PCM terminal 2F
• Short to ground circuit between ignition coil No.3 terminal C and PCM terminal 2K
• Short to ground circuit between ignition coil No.4 terminal C and PCM terminal 2W
• Short to ground circuit between ignition coil No.5 terminal C and PCM terminal 2AA
• Short to ground circuit between ignition coil No.6 terminal C and PCM terminal 2AE
• Open circuit between ignition coil terminal A and main relay No.2 terminal D
• Ignition coil malfunction

01-02–119
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0351 P0351: Ignition coil No.1 primary/secondary circuit
DTC P0352 P0352: Ignition coil No.2 primary/secondary circuit
DTC P0353 P0353: Ignition coil No.3 primary/secondary circuit
DTC P0354 P0354: Ignition coil No.4 primary/secondary circuit
DTC P0355 P0355: Ignition coil No.5 primary/secondary circuit
DTC P0356 P0356: Ignition coil No.6 primary/secondary circuit
MAIN RELAY NO.2 PCM
IGNITION COIL NO.1
4 3 9 3 5 6 8 7
A C 2A IGNITION COIL NO.1

IGNITION COIL NO.2

4 3 9 3 5 6 8 7
A C 2F IGNITION COIL NO.2

IGNITION COIL NO.3

4 3 9 3 5 6 8 7
A C 2K IGNITION COIL NO.3

IGNITION COIL NO.4

4 3 9 3 5 6 8 7
A C 2W IGNITION COIL NO.4

IGNITION COIL NO.5

4 3 9 3 5 6 8 7
A C 2AA IGNITION COIL NO.5

IGNITION COIL NO.6

4 3 9 3 5 6 8 7
A C 2AE IGNITION COIL NO.6

PCM
IGNITION COIL NO.1—NO.6
WIRING HARNESS-SIDE CONNECTOR
MAIN RELAY NO.2 WIRING HARNESS-SIDE CONNECTOR

A E
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F2A
C C A 2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

D
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–120
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT IGNITION COIL CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 10.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the ignition coil connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction? 01-02
4 INSPECT IGNITION COIL POWER SUPPLY Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Disconnect the ignition coil connector.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between ignition coil
terminal A (wiring harness-side) and body
ground.
• Is the voltage B+?
5 INSPECT IGNITION COIL SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 10.
SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between ignition coil
terminal C (wiring harness-side) and body
ground.
• Is the voltage B+?
6 INSPECT IGNITION COIL SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 10.
SHORT TO GROUND No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect continuity between ignition coil terminal
C (wiring harness-side) and body ground.
• Is there continuity?
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
8 INSPECT IGNITION COIL SIGNAL CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Inspect continuity between the following
circuits:
— Ignition coil No.1 terminal C (wiring harness-
side) and PCM terminal 2A (wiring harness-
side)
— Ignition coil No.2 terminal C (wiring harness-
side) and PCM terminal 2F (wiring harness-
side)
— Ignition coil No.3 terminal C (wiring harness-
side) and PCM terminal 2K (wiring harness-
side)
— Ignition coil No.4 terminal C (wiring harness-
side) and PCM terminal 2W (wiring harness-
side)
— Ignition coil No.5 terminal C (wiring harness-
side) and PCM terminal 2AA (wiring
harness-side)
— Ignition coil No.6 terminal C (wiring harness-
side) and PCM terminal 2AE (wiring
harness-side)
• Are there continuity?
9 INSPECT IGNITION COIL Yes Go to the next step.
• Inspect ignition coil. No Replace the ignition coil, then go to the next step.
(See 01-18-2 IGNITION COIL INSPECTION
[MZI-3.5].)
• Are there ignition coil normal?

01-02–121
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
10 VERIFY TROUBLESHOOTING OF DTC P0351, Yes Replace the PCM, then go to the next step.
P0352, P0353, P0354, P0355 and P0356 (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
COMPLETED No Go to the next step.
• Verify that all disconnected connectors
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P0420, P0430 [MZI-3.5]
WM: DTC P04XX

id0102d1880900

DTC P0420 P0420: Catalyst system efficiency below threshold (RH)

DTC P0430 P0430: Catalyst system efficiency below threshold (LH)
DETECTION • P0420 indicates right bank catalyst system efficiency is below the acceptable threshold.
CONDITION • P0430 indicates left bank catalyst system efficiency is below the acceptable threshold.
• Use of leaded fuel.
• Oil contamination
• Cylinder misfiring.
• Damaged HO2S.
• Malfunctioning CHT sensor.
• Downstream HO2S wires improperly connected.
• Fuel pressure too high.
• Damaged exhaust system pipe.
POSSIBLE • Damaged exhaust manifold.
CAUSE • Damaged muffler/tailpipe ass

Note
• Internal deterioration of a catalytic converter is usually caused by abnormal engine operation front of the
catalyst. Events that can produce higher than normal temperatures in the catalyst are particularly
suspect, such as misfiring.Incorrect HO2S signal input (e.g., rich/lean signal when engine is operating
under rich/lean conditions) can cause an abnormal temperature increase in the catalyst. CHT sensor
DTCs can indicate that the thermostat is not operating correctly or that the engine coolant level is not
filled to specification, producing above normal operating temperatures.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 INSPECT GAS LEAKAGE OF EXHAUST Yes Repair or replace malfunctioning exhaust parts, then go to
SYSTEM Step 7.
• Visually inspect for exhaust gas leakage in No Go to the next step.
exhaust system.
• Are there gas leakage?

01-02–122
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT INSTALLATION OF FRONT AND Yes Go to the next step.
REAR HO2S No Retighten sensor, then go to Step 7.
• Inspect for looseness of front and rear HO2Ss.
• Are they it normal?
6 INSPECT TWC Yes Go to the next step.
• Clear the DTC using the M-MDS. No Replace the TWC, then go to the next step.
• Cycle the ignition switch off then back to the 01-02
ON position.
• Inspect the TWC.
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P0420, Yes Replace the PCM, then go to the next step.
P0430 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P0442, P0456 [MZI-3.5]
id0102d1881000

DTC P0442 P0442: Evaporative emission system leak detected (small leak)
DTC P0456 P0456: Evaporative emission system leak detected (very small leak)
• P0442 indicates that a leak has been detected as small as 1 mm (0.04in) in the EVAP vapor management
valve solenoid system when there is less than 0.625 kPa (PID FTP_H2O displays “2.5“) bleed-up over 15 s
DETECTION at 75% fuel fill. Bleed-up and evaluation time vary as a function of fuel fill level. The vapor generation limit is
CONDITION more than 0.625 kPa (PID FTP_H2O displays “2.5“) over 120 s.
• P0456 indicates that a fuel vapor leak from an opening as small as 0.508 mm (0.020 in) has been detected
by the EVAP running loss monitor test.
• After-market EVAP hardware (such as fuel-filler cap) nonconforming to required specifications.
• Small holes or cuts in fuel vapor hoses/tubes (P0442, P0456).
POSSIBLE
• CV solenoid stays partially open on closed command.
CAUSE
• Damaged, cross-threaded or loosely installed fuel-filler cap.
• EVAP system component seals leaking.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?

01-02–123
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 VISUALLY INSPECT COMPONENTS FOR Yes Repair or install a new component if necessary. Go to Step
SMALL LEAKS 13.
• Check for presence of fuel-filler cap. Do not No Go to the next step.
tighten or check for correct installation at this
time.
• Verify that the CV solenoid valve is properly
seated on the charcoal canister.
• Visually inspect for cut or loose connections to
the fuel vapor hoses/tubes in the following
locations:
— Charcoal canister to CV solenoid valve.
— Charcoal canister to evaporative emission
valve component.
— Evaporative emission valve component to
the fuel tank (if applicable).
• Check for fuel-filler pipe damage.
• Is a concern with a hose, tube, connection, or
valve visually evident?
5 INSPECT FOR SMALL SYSTEM LEAKS FROM Yes Go to the next step.
EVAP TEST PORT No Replace a new component if necessary. Go to Step 7.
• Connect the EVAP system tester SST 218-
0002 or equivalent to the EVAP test port.
• Perform the EVAP System Leak Test.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
• Does the system pass the leak test?
6 INSPECT FOR SMALL LEAKS AT FUEL-FILLER Yes Repair or replace the component if necessary. Go to Step
CAP AND EVAPORATIVE TEST PORT 11.
• Perform the KOEO self-test. No Remove the Leak Tester. Install the fuel-filler cap. Go to
• Close CV solenoid valve using the EVAPCV Step 13.
PID.
• Using the EVAP system tester, check for leaks
around the fuel-filler cap and the evaporative
test port.
• Is a leak detected?
7 VISUALLY INSPECT FUEL-FILLER CAP Yes Replace the fuel-filler cap, then go to the next step.
• Visually inspect the fuel-filler cap for damage. No Go to Step 12.
• Is the fuel-filler cap damaged?
8 INSPECT FOR SMALL LEAK WITH TESTER Yes Go to the next step.
SET AT FILL POSITION No Go to step 10.
• Perform the KOEO self-test.
• Close CV solenoid valve using the EVAPCV
PID from the output test mode.
• Pressurize EVAP system to 3.48 kPa (PID
FTP_H2O displays “14”).
• Does the pressure hold between 3.43 and 3.53
kPa (PID FTP_H2O displays “13.80“and
“14.20“)?
9 INSPECT FOR LEAKS IN COMPLETE EVAP Yes Repair or replace the component if necessary. Go to Step
SYSTEM 12.
• Verify CV solenoid valve is closed. No Discontinue pressurizing the system. Go to the next step.
• Verify system is pressurized to 3.48 kPa (14 in-
H2O).
• Using the ultrasonic leak detector, check the
following EVAP system locations:
— EVAP return tube to CV solenoid valve.
— CV solenoid valve to charcoal canister—CV
solenoid valve component.
— Charcoal canister—CV solenoid valve
component to fuel tank.
— fuel-filler cap and fuel-filler pipe.
• Is a leak detected?

01-02–124
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
10 INSPECT FOR SMALL LEAK FROM EVAP Yes Repair or replace the component if necessary. Go to Step
RETURN TUBE TO CHARCOAL CANISTER 12.
• Disconnect the fuel tank vapor tube at the fuel No Open the CV solenoid valve. Go to the next step.
fuel vapor hose joint and plug the opening in
the hose joint.
• Perform the KOEO self-test.
• Close CV solenoid valve using the EVAPCV 01-02
PID from the output test mode.
• Pressurize the EVAP system to 3.48 kPa (14in-
H2O).
• Using the ultrasonic leak detector, check the
EVAP system from the intake manifold to the
CV solenoid valve.
• Is a leak detected?
11 INSPECT FOR SMALL LEAK BETWEEN FUEL Yes Repair or install a new component. Go to the next step.
TANK VAPOR TUBE AND FUEL TANK FILLER No Reconnect the fuel vapor tube to the fuel vapor hose joint.
PIPE Go to Step 12.
• Transfer the plug from the fuel vapor hose joint
to the fuel tank vapor tube.
• Pressurize EVAP system to 3.48 kPa (PID
FTP_H2O displays “14”).
• Using the ultrasonic leak detector, check the
fuel tank vapor tube to the fuel tank for leaks.
Check the FTP sensor, fuel tank vapor tube
and the fuel-filler pipe.
• Is a leak detected?
12 EVAP SYSTEM LEAK TEST Yes Go to the next step.
• Connect all disconnected connectors and No Leakage still exists. Locate leak point and repair. Repeat
hoses. this step.
• Perform the EVAP System Leak Test.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
• Are the test results normal?
13 VERIFY TROUBLESHOOTING OF DTC P0442, Yes Replace the PCM, then go to the next step.
P0456 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
14 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
SOKYU_WM: DTC P04XX

01-02–125
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0443 [MZI-3.5]
id0102d1807600

DTC P0443 Purge solenoid valve circuit

DETECTION • The PCM monitors the state of the purge solenoid valve circuit output driver. The test fails when the signal
CONDITION moves outside the minimum or maximum limit for the commanded state.
• Purge solenoid valve malfunction
• Connector or terminal malfunction
• Short to ground between purge solenoid valve terminal B and PCM terminal 1BC
POSSIBLE
• Open circuit between main relay No.1 terminal D and purge solenoid valve terminal A
CAUSE
• Short to power supply between purge solenoid valve terminal B and PCM terminal 1BC
• Open circuit between purge solenoid valve terminal B and PCM terminal 1BC
• PCM malfunction
PCM

MAIN RELAY NO.1 PURGE SOLENOID VALVE

9
3 4 5 6 8 7
A B 1BC
3

PCM
WIRING HARNESS-SIDE CONNECTOR

PURGE SOLENOID VALVE

WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

B A 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT PURGE SOLENOID VALVE Yes Repair or replace suspected part, then go to Step 10.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect purge solenoid valve connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–126
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT POWER SUPPLY CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between purge solenoid valve
terminal A and body ground.
• Is voltage B+? 01-02
5 INSPECT PURGE SOLENOID VALVE CONTROL Yes Repair or replace suspected part, then go to Step 10.
CIRCUIT FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between purge solenoid
valve control terminal B and body ground.
• Is voltage B+?
6 INSPECT PURGE SOLENOID VALVE CONTROL Yes Repair or replace suspected part, then go to the Step 10.
CIRCUIT FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between purge solenoid
valve control terminal B and body ground.
• Is there continuity?
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
8 INSPECT PURGE SOLENOID VALVE CONTROL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to the Step 10.
• Turn the ignition switch off.
• Inspect continuity between purge solenoid
valve terminal B and PCM terminal 1BC.
• Is there continuity?
9 INSPECT PURGE SOLENOID VALVE Yes Replace purge solenoid valve (See 01-16-8 PURGE
• Inspect the purge solenoid valve. SOLENOID VALVE REMOVAL/INSTALLATION [MZI-3.5].),
(See 01-16-8 PURGE SOLENOID VALVE then go to Step 10.
INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
10 VERIFY TROUBLESHOOTING OF DTC P0443 Yes Replace PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear DTC from PCM memory using M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE same DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P04XX

01-02–127
1890-1U-06H(01-02).fm 128 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0446 [MZI-3.5]
id0102d1807700

DTC P0446 CV solenoid valve control circuit

• Monitors the CV solenoid valve circuit for an electrical failure. The test fails when the signal moves outside
DETECTION
the minimum or maximum allowable calibrated parameters for a specified canister vent duty cycle by PCM
CONDITION
command.
• CV solenoid valve malfunction
• Connector or terminal malfunction
• Short to ground between CV solenoid valve terminal B and PCM terminal 1Z
POSSIBLE
• Open circuit between battery and CV solenoid valve terminal A
CAUSE
• Short to power supply between CV solenoid valve terminal B and PCM terminal 1Z
• Open circuit between CV solenoid valve terminal B and PCM terminal 1Z
• PCM malfunction
PCM

BATTERY CV SOLENOID VALVE

9
3 4 5 6 8 7
A B 1Z
3

PCM
WIRING HARNESS-SIDE CONNECTOR
CV SOLENOID VALVE
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

B A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT CV SOLENOID VALVE CONNECTOR Yes Repair or replace suspected part, then go to Step 10.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect CV solenoid valve connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–128
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT POWER SUPPLY CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between CV solenoid valve
terminal A and body ground.
• Is voltage B+? 01-02
5 INSPECT CV SOLENOID VALVE CONTROL Yes Repair or replace suspected part, then go to Step 10.
CIRCUIT FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between CV solenoid
valve control terminal B and body ground.
• Is voltage B+?
6 INSPECT CV SOLENOID VALVE CONTROL Yes Repair or replace suspected part, then go to the Step 10.
CIRCUIT FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between CV solenoid
valve control terminal B and body ground.
• Is the continuity?
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
8 INSPECT CV SOLENOID VALVE CONTROL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to the Step 10.
• Turn the ignition switch off.
• Inspect continuity between CV solenoid valve
terminal B and PCM terminal 1Z.
• Is there continuity?
9 INSPECT CV SOLENOID VALVE Yes Replace CV solenoid valve (See 01-16-5 CHARCOAL
• Inspect the CV solenoid valve. CANISTER, CANISTER VENT (CV) SOLENOID VALVE,
(See 01-16-6 CHARCOAL CANISTER, AIR FILTER COMPONENT REMOVAL/INSTALLATION
CANISTER VENT (CV) SOLENOID VALVE, [MZI-3.5].), then go to Step 10.
AIR FILTER COMPONENT INSPECTION No Go to the next step.
[MZI-3.5].)
• Is there any malfunction?
10 VERIFY TROUBLESHOOTING OF DTC P0446 Yes Replace PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear DTC from PCM memory using M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE same DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–129
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0451 [MZI-3.5]
id0102d1873600

DTC P0451 Fuel tank pressure sensor range/performance

Note
• For some vehicle applications, DTC P0451 is set for a fuel tank pressure sensor range (offset) concern.
The DTC P0454 replaces the original P0451 for intermittent (noisy) sensor concerns. Until the phase in
DETECTION
process is complete, noisy or offset fuel tank pressure sensor concerns may set DTC P0451.
CONDITION
• The fuel tank pressure changes more than 14 inches of water in 0.10 s. Fuel tank pressure sensor output is
offset by + /- 1.7 inches of water.
• Intermittent open or short in the fuel tank pressure sensor or the fuel tank pressure sensor signal
POSSIBLE • Fuel tank pressure sensor malfunction
CAUSE • Connector or terminal malfunction
• PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 CLEAR AND ATTEMPT TO RETRIEVE THE DTC Yes Go to the next step.
• Clear the DTC from the PCM memory using No DTC troubleshooting completed.
the M-MDS.
• Turn the ignition switch to the ON position
(Engine running).
• Run the engine for approx. 10 s.
• Check for continuous memory DTCs.
• Is the same DTC present?
5 INSPECT FUEL TANK PRESSURE AND PCM Yes Repair or replace suspected part, then go to Step 8.
SENSOR CONNECTOR FOR POOR No Go to the next step.
CONNECTION
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT THE FUEL TANK PRESSURE Yes Replace evaporative hose component, then go to Step 8.
• Inspect the MAF sensor. (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-
(See 01-40-30 FUEL TANK PRESSURE 3.5].)
SENSOR INSPECTION [MZI-3.5].) No Go to the next step.
• Is there malfunction?
7 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?

01-02–130
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
8 VERIFY TROUBLESHOOTING OF DTC P0451 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using 01-02
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Start the engine and wait for approx. 10s.
• Is the PENDING CODE for the DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-12 DTC TABLE [MZI-3.5])
(See01-02-8 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[MZI-3.5])
• Are any DTCs present?

End Of Sie
DTC P0452 [MZI-3.5]
id0102d1873700

DTC P0452 Fuel tank pressure sensor low input

DETECTION • The PCM monitors the evaporative emission (EVAP) control system fuel tank pressure sensor input signal
CONDITION to the PCM. The test fails when the signal average drops below a minimum allowable calibrated parameter.
• Fuel tank pressure sensor malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Short to ground between fuel tank pressure sensor terminal A and PCM terminal 1AB
• Fuel tank pressure sensor signal circuit and ground circuit for short each other
FUEL TANK PRESSURE SENSOR PCM

3
C 1U

3 5
6 A 1AB

3 5
B 1AL

PCM
WIRING HARNESS-SIDE CONNECTOR
FUEL TANK PRESSURE SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

C B A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

01-02–131
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ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FUEL TANKE PRESSURE SENSOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel tank pressure sensor
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 VERIFY FUEL TANK PRESSURE SIGNAL Yes Repair or replace suspected part, then go to Step 7.
CIRCUIT FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between fuel tank
pressure sensor terminal A (wiring harness-
side) and body ground.
• Is there continuity?
5 INSPECT FUEL TANKE PRESSURE SENSOR Yes Go to the next step.
SIGNAL CIRCUIT AND GROUND CIRCUIT FOR No Repair or replace suspected part, then go to Step 7.
SHORT EACH OTHER
• Turn the ignition switch off.
• Disconnect the fuel tank pressure sensor and
PCM connector.
• Measure resistance between PCM terminal
1AB (wiring harness-side) and PCM terminal
1AL (wiring harness-side)
• Is the resistance more than 10 kilohms?
6 INSPECT FUEL TANKE PRESSURE SENSOR Yes Go to the next step.
• Perform the fuel tank pressure sensor No Replace the evaporative hose component, then go to the
inspection. next step.
(See 01-40-30 FUEL TANK PRESSURE (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-
SENSOR INSPECTION [MZI-3.5].) 3.5].)
• Is the fuel tank pressure sensor normal?
7 VERIFY TROUBLESHOOTING OF DTC P0452 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Turn ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and warm it up completely.
• Is same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–132
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0453 [MZI-3.5]
id0102d1873800

DTC P0453 Fuel tank pressure sensor high input

DETECTION • The PCM monitors the evaporative emission (EVAP) control system fuel tank pressure sensor input signal
CONDITION to the PCM. The test fails when the signal average jumps above a minimum allowable calibrated parameter.
• Fuel tank pressure sensor malfunction
• Connector or terminal malfunction
• Open circuit between fuel tank pressure sensor terminal A and PCM terminal 1AB 01-02
POSSIBLE • Open circuit between fuel tank pressure sensor terminal B and PCM terminal 1AL
CAUSE • Short to the constant voltage supply circuit between fuel tank pressure sensor terminal A and PCM
terminal 1AB
• Short to power supply between fuel tank pressure sensor terminal C and PCM terminal 1U
• Fuel tank pressure sensor power circuit and signal circuit are shorted each other
FUEL TANK PRESSURE SENSOR PCM

3 7 5
C 1U

3 6 7 5
8 A 1AB

3 6 5
B 1AL

PCM
WIRING HARNESS-SIDE CONNECTOR
FUEL TANK PRESSURE SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

C B A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?

01-02–133
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT FUEL TANK PRESSURE SENSOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect fuel tank pressure sensor
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 VERIFY FUEL TANK PRESSURE SENSOR Yes Repair or replace suspected part, then go to Step 9.
SIGNAL CIRCUIT FOR SHORT TO POWER No Go to the next step.
SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals:
— Fuel tank pressure sensor terminal A (wiring
harness-side) and body ground.
— Fuel tank pressure sensor terminal C (wiring
harness-side) and body ground.
• Are there voltage B+?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel tank pressure sensor and
PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
6 VERIFY FUEL TANK PRESSURE SENSOR Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Inspect for continuity between the following
circuits:
— Fuel tank pressure sensor connector
terminal A (harness-side) and PCM
connector terminal 1AB.
— Fuel tank pressure sensor connector
terminal B (harness-side) and PCM
connector terminal 1AL.
• Are there continuity?
7 INSPECT FUEL TANK PRESSURE SENSOR Yes Go to the next step.
SIGNAL CIRCUIT AND POWER CIRCUIT FOR No Repair or replace suspected part, then go to Step 9.
SHORT EACH OTHER
• Turn the ignition switch off.
• Disconnect the fuel tank pressure sensor and
PCM connector.
• Measure resistance between PCM connector
terminal 1U (harness-side) and CM connector
terminal 1AB (harness-side).
• Is the resistance more than 10 kilohms?
8 INSPECT FUEL TANK PRESSURE SENSOR Yes Go to the next step.
• Inspect the fuel tank pressure sensor. No Replace the evaporative hose component, then go to the
(See 01-40-30 FUEL TANK PRESSURE next step.
SENSOR INSPECTION [MZI-3.5].) (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-
• Is the fuel tank pressure sensor normal? 3.5].)
9 VERIFY TROUBLESHOOTING OF DTC P0453 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Turn ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and warm it up completely.
• Is same DTC present?

01-02–134
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie 01-02

DTC P0454 [MZI-3.5]
id0102d1873900

DTC P0454 Fuel tank pressure sensor intermittent

DETECTION
• The fuel tank pressure changes more than 14 inches of water in 0.10 s.
CONDITION
POSSIBLE • Intermittent open or short in the fuel tank pressure sensor or the fuel tank pressure sensor signal
CAUSE • Fuel tank pressure sensor malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Perform the “INTERMITTENT CONCERN
position (Engine off). TROUBLESHOOTING”. Then go to the next step.
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 VERIFY TROUBLESHOOTING OF DTC P0454 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–135
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0455 [MZI-3.5]
id0102d1815500

DTC P0455 Evaporative emission system leak detected (gross leak/no flow)
DETECTION • P0455 indicates that a substantial leak or blockage has been detected in the EVAP system when there is -
CONDITION 1.74 kPa (PID FTP_H2O displays “-7.0“) or less vacuum for a 30 seconds evaluation time.
• After-market EVAP hardware (such as fuel-filler cap) not conforming to required specifications.
• Disconnected or cracked fuel chopping timer tube, CV solenoid valve outlet tube or EVAP return tube.
• CV solenoid valve stuck closed
• Damaged or missing fuel-filler cap.
• Insufficient fuel-filler cap installation.
POSSIBLE
• Loose fuel vapor hose/tube connections to EVAP system components.
CAUSE
• Blockages or restrictions in fuel vapor hoses/tubes.
• Rollover valve blocked or fuel shut-off valve.
• CV solenoid valve stuck open.
• Mechanically inoperative Fuel tank pressure sensor.
• Damaged charcoal canister.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
4 VISUALLY INSPECT FOR LARGE EVAP Yes Repair or replace the EVAP components if necessary.
SYSTEM LEAK (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-
• Check for the presence of a fuel-filler cap. Do 3.5].)
not tighten or check for correct installation at (See 01-40-30 FUEL TANK PRESSURE SENSOR
this time. INSPECTION [MZI-3.5].)
• Verify that both the input port vacuum hose and (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT
EVAP return tube are attached to the CV (CV) SOLENOID VALVE, AIR FILTER COMPONENT
solenoid valve. REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that the CV solenoid valve is properly Go to Step 7.
attached to the charcoal canister. No Go to the next step.
• Visually inspect for disconnected or cracked
fuel vapor hoses/tubes between the intake
manifold and the following components:
— CV solenoid valve
— Charcoal canister
— Fuel shut-off valve
• Check for damage to the fuel-filler pipe and the
fuel tank.
• Is a concern visually evident?
5 INSPECT FOR EVAP SYSTEM LEAKS Yes Go to the next step.
• Disconnect the EVAP return tube from the No Verify that the fuel-filler cap is installed correctly. Repair or
intake manifold and plug the EVAP return tube. install a new components if necessary. Go to Step 8.
• Connect the EVAP System Leak Tester to the
EVAP test port.
• Perform the EVAP System Leak Test.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
• Does the pressure stay above 1.99 kPa (PID
FTP_H2O displays “8“)?

01-02–136
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
6 INSPECT FOR BLOCKAGE BETWEEN CV Yes Go to the next step.
SOLENOID VALVE AND FUEL VAPOR HOSE No Replace the fuel tank vapor line(s). Go to Step 8.
JOINT
• Perform the KOEO self-test.
• Using M-MDS tester, select the Diagnostic
Data Link.
• Select the PCM. 01-02
• Select the Active Command Modes.
• Select the Output Test Mode.
• Close the CV solenoid valve using the EVMV
PID.
• Pressurize the EVAP system to 3.48 kPa (PID
FTP_H2O displays “14“).
• Press STOP (#4) on M-MDS tester to open the
EVMV.
• Does the pressure drop immediately?
7 INSPECT FOR MALFUNCTIONING CV Yes Replace the CV solenoid valve.
SOLENOID VALVE OR FUEL TANK PRESSURE (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT
SENSOR (CV) SOLENOID VALVE, AIR FILTER COMPONENT
• Were both P0455 and P1443 present at Step REMOVAL/INSTALLATION [MZI-3.5]01-16 EVAPORATIVE
1? EMISSION CANISTERPURGE VALVE.)
Go to the next step.
No Replace the evaporative hose component.
(See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-
3.5].)
Go to the next step.
8 EVAP SYSTEM LEAK TEST Yes Go to the next step.
• Connect all disconnected connectors and No Leakage still exists. Locate leak point and repair. Repeat
hoses. this step.
• Perform the EVAP System Leak Test.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
• Are the test results normal?
9 VERIFY TROUBLESHOOTING OF DTC P0455 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–137
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0457 [MZI-3.5]
id0102d1881100

DTC P0457 Evaporative emission system leak detected (fuel cap loose/off)
DETECTION • P0457 indicates that the initial vacuum could not be achieved after a refueling event and the purge vapor
CONDITION flow is excessive (gross leak).
POSSIBLE
• Missing or loose fuel filler cap.
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?

Note
• If DTC P0455 is present, diagnose that DTC
first.
(See 01-03-60 ENGINE CONTROL
SYSTEM OPERATION INSPECTION [MZI-
3.5].)
4 INSPECT FOR MISSING OR LEAKING FUEL Yes Repair or replace if necessary. Go to the next step.
FILLER CAP No Go to Step 6.
• Check for missing or loose fuel filler cap.
• Check for possible cross-threaded fuel filler
cap.
• Is a concern present?
5 EVAP SYSTEM LEAK TEST Yes Go to Step 6.
• Perform the EVAP system leak test. No Leakage still exists. Go to the P0455 Troubleshooting.
(See 01-01 01-03-60 ENGINE CONTROL (See 01-03-60 ENGINE CONTROL SYSTEM OPERATION
SYSTEM OPERATION INSPECTION [MZI- INSPECTION [MZI-3.5].)
3.5].)
• Are the test results normal?
6 VERIFY TROUBLESHOOTING OF DTC P0457 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–138
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0460 [MZI-3.5]
id0102d1821000

DTC P0460 Fuel level sensor circuit

• The PCM monitors the fuel level input communications network message for a concern. The test fails when
DETECTION the PCM determines that the value of the fuel level input signal is stuck. The PCM calculates the amount of
CONDITION fuel used during operation. If the fuel level input signal does not change or does not correspond with the
calculated fuel usage, the DTC is set.
• Empty fuel tank 01-02
• Fuel pump malfunction
• Incorrectly installed fuel gauge
POSSIBLE • Instrument cluster malfunction
CAUSE • Fuel level input signal circuit malfunction
• Overfilled fuel tank
• Fuel gauge malfunction
• Stuck float arm

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY REPAIR INFORMATION AVAILABILITY Yes Perform repair or diagnosis according to the available
• Verify related Service Bulletins availability. Service Bulletins. If the vehicle is not repaired, go to the
• Is any related Service Bulletins available? next step.
No Go to the next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 VERIFY STORED DTC IN INSTRUMENT Yes Go to the appropriate DTC inspection.
CLUSTER (See 09-02J-2 DTC TABLE [INSTRUMENT CLUSTER].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify stored DTCs in instrument cluster.
• Is other DTCs present?
5 VERIFY TROUBLESHOOTING OF DTC P0460 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO/KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–139
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0461 [MZI-3.5]
id0102d1808000

DTC P0461 Fuel gauge sender unit range/performance problem

• The PCM monitors the fuel level input communications network message for a concern. The test fails when
DETECTION
the fuel level input signal repeatedly moves in and out of range, exceeding the minimum or maximum
CONDITION
allowable calibrated parameters for a specified fuel fill percentage in the fuel tank.
POSSIBLE • Excessive electrical noise
CAUSE • Fuel level input signal circuit malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY REPAIR INFORMATION AVAILABILITY Yes Perform repair or diagnosis according to the available
• Verify related Service Bulletins availability. Service Bulletins. If the vehicle is not repaired, go to the
• Is any related Service Bulletins available? next step.
No Go to the next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 VERIFY STORED DTC IN INSTRUMENT Yes Go to the appropriate DTC inspection.
CLUSTER (See 09-02J-2 DTC TABLE [INSTRUMENT CLUSTER].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify stored DTCs in instrument cluster.
• Is other DTCs present?
5 VERIFY TROUBLESHOOTING OF DTC P0461 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO/KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–140
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
DTC P0462 [MZI-3.5]
id0102d1808100

DTC P0462 Fuel gauge sender unit circuit low input

• The PCM) monitors the fuel level input communications network message for a concern. The test fails if the
DETECTION
fuel level input signal is less than the minimum allowable calibrated parameter for a specified fuel-fill
CONDITION
percentage in the fuel tank.
• Empty fuel tank
• Fuel pump malfunction 01-02
POSSIBLE • Incorrectly installed fuel gauge
CAUSE • Instrument cluster malfunction
• Fuel gauge malfunction
• Fuel level input signal circuit malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY REPAIR INFORMATION AVAILABILITY Yes Perform repair or diagnosis according to the available
• Verify related Service Bulletins availability. Service Bulletins. If the vehicle is not repaired, go to the
• Is any related Service Bulletins available? next step.
No Go to the next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 VERIFY STORED DTC IN INSTRUMENT Yes Go to the appropriate DTC inspection.
CLUSTER (See 09-02J-2 DTC TABLE [INSTRUMENT CLUSTER].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify stored DTCs in instrument cluster.
• Is other DTCs present?
5 VERIFY TROUBLESHOOTING OF DTC P0462 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO/KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P0463 [MZI-3.5]
id0102d1808200

DTC P0463 Fuel gauge sender unit circuit high input

• The PCM monitors the fuel level input communications network message for a concern. The test fails if the
DETECTION
fuel level input signal is more than the maximum allowable calibrated parameter for a specified fuel-fill
CONDITION
percentage in the fuel tank.
• Fuel pump malfunction
• Incorrectly installed fuel gauge
POSSIBLE • Instrument cluster malfunction
CAUSE • Fuel level input signal circuit malfunction
• Overfilled fuel tank
• Fuel gauge malfunction

01-02–141
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY REPAIR INFORMATION AVAILABILITY Yes Perform repair or diagnosis according to the available
• Verify related Service Bulletins availability. Service Bulletins. If the vehicle is not repaired, go to the
• Is any related Service Bulletins available? next step.
No Go to the next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 VERIFY STORED DTC IN INSTRUMENT Yes Go to the appropriate DTC inspection.
CLUSTER (See 09-02J-2 DTC TABLE [INSTRUMENT CLUSTER].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify stored DTCs in instrument cluster.
• Is other DTCs present?
5 VERIFY TROUBLESHOOTING OF DTC P0463 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO/KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P0480 [MZI-3.5]
SOKYU_WM: DTC P04XX

id0102d1807400

DTC P0480 Fan control circuit

DETECTION • This test inspect the fan control circuit. The DTC sets if the PCM detects the voltage on the fan control
CONDITION variable circuit is not within the expected range.
• Connector or terminal malfunction
• Fan control module malfunction
Dual fan control module
— Open circuit between fan control module No.1 terminal 1B and PCM terminal 1AM
— Short to power supply between fan control module No.1 terminal 1B and PCM terminal 1AM
— Short to ground circuit between fan control module No.1 terminal 1B and PCM terminal 1AM
— Open circuit between fan control module No.2 terminal B and PCM terminal 1AM
— Short to power supply between fan control module No.2 terminal B and PCM terminal 1AM
— Short to ground circuit between fan control module No.2 terminal B and PCM terminal 1AM
POSSIBLE
— Open circuit between fan control module No.1 terminal 1A and cooling fan relay No.1 terminal E
CAUSE
— Open circuit between fan control module No.1 terminal 1C and body ground
— Open circuit between fan control module No.2 terminal A and cooling fan relay No.2 terminal E
— Open circuit between fan control module No.2 terminal C and body ground
Single fan control module
— Open circuit between fan control module terminal 1B and PCM terminal 1AM
— Short to power supply between fan control module terminal 1B and PCM terminal 1AM
— Short to ground circuit between fan control module terminal 1B and PCM terminal 1AM
— Open circuit between fan control module terminal 1C and cooling fan relay terminal E
— Open circuit between fan control module terminal 1A and body ground

01-02–142 Revised 1/2007 (Ref. No. R009/07)

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
DTC P0480 Fan control circuit

DUAL FAN CONTROL MODULE COOLING FAN

RELAY NO.1 PCM
FAN CONTROL MODULE NO.1
5 3 3 4
1C 1A
01-02
3 6 7 9 8
1B 1AM

COOLING FAN
FAN CONTROL MODULE NO.2 RELAY NO.2
5 3 3 4
C A

3 6 7 9
B

SINGLE FAN CONTROL MODULE

FAN CONTROL MODULE COOLING FAN RELAY PCM

5 3 3 4
1A 1C

3 6 7 9 8
1B 1AM

FAN CONTROL MODULE PCM

WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1C 1B 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

FAN CONTROL MODULE NO.1 FAN CONTROL MODULE NO.2

WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR

1C 1B 1A C B A

Revised 1/2007 (Ref. No. R009/07) 01-02–143

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT FAN CONTROL MODULE Yes Repair or replace suspected part, then go to Step 10.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect fan control module connector.
• Inspect for poor connection (such as damaged,
pulled-out pins, corrosion, etc.).
• Are there any malfunction?
4 INSPECT FAN CONTROL MODULE POWER Yes Go to the next step.
SUPPLY CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between the following circuits:
Dual fan control module
— Fan control module No.1 terminal 1A (wiring
harness-side) and body ground.
— Fan control module No.2 terminal A (wiring
harness-side) and body ground.
Single fan control module
— Fan control module terminal 1C (wiring
harness-side) and body ground.
• Are there voltage B+?
5 INSPECT FAN CONTROL MODULE GROUND Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch off.
• inspect for continuity between the following
circuits:
Dual fan control module
— Fan control module No.1 terminal 1C
(wiring harness-side) and body ground.
— Fan control module No.2 terminal C (wiring
harness-side) and body ground.
Single fan control module
— Fan control module terminal 1A (wiring
harness-side) and body ground.
• Are there continuity?
6 INSPECT FAN CONTROL CIRCUIT FOR SHORT Yes Repair or replace suspected part, then go to Step 10.
TO POWER No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
circuits:
Dual fan control module
— Fan control module No.1 terminal 1B (wiring
harness-side) and body ground.
— Fan control module No.2 terminal B (wiring
harness-side) and body ground.
Single fan control module
— Fan control module terminal 1B (wiring
harness-side) and body ground.
• Are there voltage B+?

01-02–144 Revised 1/2007 (Ref. No. R009/07)

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
STEP INSPECTION ACTION
7 INSPECT FAN CONTROL CIRCUIT FOR SHORT Yes Repair or replace suspected part, then go to Step 10.
TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect continuity between the following
circuits:
Dual fan control module
— Fan control module No.1 terminal 1B (wiring 01-02
harness-side) and body ground.
— Fan control module No.2 terminal B (wiring
harness-side) and body ground.
Single fan control module
— Fan control module terminal 1B (wiring
harness-side) and body ground.
• Are there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
9 INSPECT FAN CONTROL CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to the next step.
• Inspect continuity between the following
circuits:
Dual fan control module
— Fan control module No.1 terminal 1B (wiring
harness-side) and PCM terminal 1AM
(wiring harness-side).
— Fan control module No.2 terminal B (wiring
harness-side) and PCM terminal 1AM
(wiring harness-side).
Single fan control module
— Fan control module terminal 1B (wiring
harness-side) and PCM terminal 1AM
(wiring harness-side).
• Are there continuity?
10 VERIFY TROUBLESHOOTING OF DTC P0480 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Are any DTCs present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P0505 [MZI-3.5]
SOKYU_WM: DTC P05XX

id0102d1808500

DTC P0505 Idle speed control system problem

DETECTION • The PCM attempts to control engine speed during the KOER self-test. The test fails when the desired
CONDITION engine speed could not be reached or controlled during the self-test.

Revised 1/2007 (Ref. No. R009/07) 01-02–145

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
ON-BOARD DIAGNOSTIC [MZI-3.5]
DTC P0505 Idle speed control system problem
• Failure mode effects management condition is present
• Intake air restriction
• Exhaust restriction
• Sludged throttle body
• Vacuum leakage
POSSIBLE • Throttle body malfunction
CAUSE • PCM malfunction

Note
• This DTC is informational only and it may be accompanied by other DTCs. Diagnose other DTCs first. If
other DTCs are not present inspect the intake air system for air restrictions, vacuum leaks, and damage.
If no concerns are present, clear the DTC and repeat the self-test.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
4 INSPECT AIR CLEANER ELEMENT Yes Replace the air cleaner element, then go to Step 9.
• Remove air cleaner element with the engine No Go to the next step.
running.
• Is the engine speed increased?
5 INSPECT FOR AIR SUCTION AT INTAKE AIR Yes Repair or replace the suspected part, then go to Step 9.
SYSTEM No Go to the next step.
• Inspect for air leakage at the following:
— Around connection of dynamic chamber and
intake manifold
— Around connection of intake manifold and
cylinder head
• Is air leakage found?
6 INSPECT THROTTLE BODY PASSAGE Yes Clean or replace the throttle body passage, then go to Step
• Is the throttle body clogged? 9.
No Go to the next step.
7 INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect the engine compression. No Overhaul the engine, then go to the next step.
(See 01-10-9 COMPRESSION INSPECTION
[MZI-3.5].)
• Is the engine compression normal?
8 INSPECT FOR RESTRICTION IN EXHAUST Yes Replace malfunctioning part, then go to the next step.
SYSTEM AND TWC No Go to the next step.
• Is there any restriction?
9 VERIFY TROUBLESHOOTING OF DTC P0505 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO and KOER self-test.
• Retrieve the DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?

01-02–146
1890-1U-06H(01-02).fm 147 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie 01-02

DTC P0506 [MZI-3.5]
id0102d1808600

DTC P0506 IAC system RPM lower than expected

DETECTION
• This DTC is set when the PCM detects an engine idle speed that is less than the desired engine speed.
CONDITION
• Engine mechanical concern
• Intake air restriction
• Exhaust restriction
POSSIBLE
• Sludged throttle body
CAUSE
• Vacuum leakage
• Throttle body malfunction
• PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, then go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING OR STORED Yes Repair applicable DTCs.
DTCS (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify pending code or stored DTCs using the
M-MDS.
• Is other DTC present?
4 INSPECT AIR CLEANER ELEMENT Yes Replace the air cleaner element, then go to Step 7.
• Remove air cleaner element with the engine No Go to the next step.
running.
• Is the engine speed increased?
5 INSPECT INTAKE AIR SYSTEM FOR Yes Repair or replace the malfunctioning part, then go to Step
EXCESSIVE AIR SUCTION 7.
• Visually inspect the hose in intake air system No Go to the next step.
for damages.
• Is there any malfunction?
6 INSPECT THROTTLE BODY PASSAGE Yes Clean or replace the throttle body passage, then go to the
• Is the throttle body clogged? next step.
No Go to the next step.
7 VERIFY TROUBLESHOOTING OF DTC P0506 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Start the engine.
• Clear the DTC from the PCM memory using
the M-MDS.
• Depress brake pedal for 14 s or more.
• Is PENDING CODE for this DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?
End Of Sie

01-02–147
1890-1U-06H(01-02).fm 148 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0507 [MZI-3.5]
id0102d1808700

DTC P0507 IAC system RPM higher than expected

DETECTION
• This DTC is set when the PCM detects an engine idle speed that is more than the desired engine speed.
CONDITION
• Intake air leak after throttle body
• Vacuum leakage
POSSIBLE
• EVAP system malfunction
CAUSE
• Throttle body malfunction
• PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, then go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING OR STORED Yes Repair applicable DTCs.
DTCS (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify pending code or stored DTCs using the
M-MDS.
• Is other DTC present?
4 INSPECT AIR CLEANER ELEMENT Yes Replace the air cleaner element, then go to Step 7.
• Remove air cleaner element with the engine No Go to the next step.
running.
• Is the engine speed increased?
5 INSPECT INTAKE AIR SYSTEM FOR Yes Repair or replace the malfunctioning part, then go to Step
EXCESSIVE AIR SUCTION 7.
• Visually inspect the hose in intake air system No Go to the next step.
for looseness or damages.
• Is there any malfunction?
6 INSPECT THROTTLE BODY PASSAGE Yes Clean or replace the throttle body passage, then go to Step
• Is the throttle body clogged? 7.
No Go to the next step.
7 VERIFY TROUBLESHOOTING OF DTC P0507 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Start the engine.
• Clear the DTC from the PCM memory using
the M-MDS.
• Depress brake pedal for 14 s or more.
• Is PENDING CODE for this DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P050E [MZI-3.5]
WM: DTC P05XX

id0102d1870100

DTC P050E
Cold start engine exhaust temperature out of range
• The PCM calculates the actual catalyst warm up temperature during a cold start. The PCM then compares
DETECTION the actual temperature to the expected catalyst temperature model. The difference between the actual and
CONDITION expected temperatures is a ratio. When this ratio exceeds the calibrated value this DTC is set and the
malfunction indicator lamp (MIL) illuminates.

01-02–148
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P050E Cold start engine exhaust temperature out of range
• Intake air restriction
• Exhaust restriction
POSSIBLE • Mechanical concern with the engine
CAUSE • Throttle body malfunction
• Vacuum leakage
• PCM malfunction
01-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 INSPECT AIR CLEANER ELEMENT Yes Replace the air cleaner element, then go to Step 9.
• Remove air cleaner element with the engine No Go to the next step.
running.
• Is the engine speed increased?
5 INSPECT INTAKE AIR SYSTEM FOR Yes Repair or replace the malfunctioning part, then go to Step
EXCESSIVE AIR SUCTION 9.
• Visually inspect the hose in intake air system No Go to the next step.
for looseness or damages.
• Is there any malfunction?
6 INSPECT THROTTLE BODY PASSAGE Yes Clean or replace the throttle body passage, then go to Step
• Is the throttle body clogged? 9.
No Go to the next step.
7 INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect the engine compression. No Overhaul the engine, then go to Step 9.
(See 01-10-9 COMPRESSION INSPECTION
[MZI-3.5].)
• Is the engine compression normal?
8 INSPECT FOR RESTRICTION IN EXHAUST Yes Replace malfunctioning part, then go to the next step.
SYSTEM AND TWC No Go to the next step.
• Is there any restriction?
9 VERIFY TROUBLESHOOTING OF DTC P050E Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–149
1890-1U-06H(01-02).fm 150 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P053A [MZI-3.5]
id0102d1871500

DTC P053A PCV valve heater control circuit/open

DETECTION
• This DTC is set when the PCM detects a PCV valve heater circuit malfunction.
CONDITION
• Open circuit between PCV valve heater control terminal A and main relay No.1
• Open circuit between PCV valve heater fitting terminal A and main relay No.1
• Short to ground circuit between PCV valve heater control terminal B and PCM terminal 2BL
• Short to ground circuit between PCV valve heater fitting terminal B and PCM terminal 2AU
POSSIBLE • Short to power circuit between PCV valve heater control terminal B and PCM terminal 2BL
CAUSE • Short to power circuit between PCV valve heater fitting terminal B and PCM terminal 2AU
• Open circuit between PCV valve heater control terminal B and PCM terminal 2BL
• Open circuit between PCV valve heater fitting B and PCM terminal 2AU
• Connector or terminal malfunction
• Damaged PCV heater assembly

01-02–150
1890-1U-06H(01-02).fm 151 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P053A PCV valve heater control circuit/open
MAIN RELAY NO.1
PCV VALVE HEATER CONTROL PCM

3 4
A

9 01-02
3 5 6 8 7
B 2BL PCV VALVE HEATER CONTROL

PCV VALVE HEATER FITTING

3 4
A

9
3 5 6 8 7
B 2AU PCV VALVE HEATER FITTING

PCV VALVE HEATER CONTROL PCM

WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

PCV VALVE HEATER FITTING

WIRING HARNESS-SIDE CONNECTOR

B A

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.

01-02–151
1890-1U-06H(01-02).fm 152 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT PCV VALVE HEATER CONTROL AND Yes Repair or replace suspected part, then go to Step 10.
PCV VALVE HEATER FITTING CONNECTOR No Go to the next step.
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect PCV valve heater control and PCV
valve heater fitting connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT POWER SUPPLY CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect the voltage between the following
circuit:
— PCV valve heater control terminal A (wiring
harness-side) and body ground
— PCV valve heater fitting terminal A (wiring
harness-side) and body ground
• Are there voltage B+?
5 INSPECT PCV VALVE HEATER CONTROL AND Yes Repair or replace suspected part, then go to Step 10.
PCV VALVE HEATER FITTING CIRCUIT FOR No Go to the next step.
SHORT TO POWER SUPPLY
• Turn the ignition switch to the ON position
(Engine off).
• Inspect for continuity between the following
circuit:
— PCV valve heater control terminal B (wiring
harness-side) and body ground
— PCV valve heater fitting terminal B (wiring
harness-side) and body ground
• Are there voltage B+?
6 INSPECT PCV VALVE HEATER CONTROL AND Yes Repair or replace suspected part, then go to Step 10.
PCV VALVE HEATER FITTING CIRCUIT FOR No Go to the next step.
SHORT TO GROUND
• Inspect for continuity between the following
circuit:
— PCV valve heater control terminal B (wiring
harness-side) and body ground
— PCV valve heater fitting terminal B (wiring
harness-side) and body ground
• Are there continuity?
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
8 INSPECT PCV VALVE HEATER CONTROL AND Yes Go to the next step.
PCV VALVE HEATER FITTING FOR OPEN No Repair or replace suspected part, then go to Step 10.
CIRCUIT
• Inspect for continuity between the following
circuit:
— PCV valve heater control terminal B (wiring
harness-side) and PCM terminal 2BL (wiring
harness-side)
— PCV valve heater fitting B (wiring harness-
side) and PCM terminal 2AU (wiring
harness-side)
• Are there continuity?

01-02–152
1890-1U-06H(01-02).fm 153 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 INSPECT PCV VALVE HEATER CONTROL AND Yes Replace the malfunctioning part, then go to the next step.
PCV VALVE HEATER FITTING No Go to the next step.
• Inspect the PCV valve heater control and PCV
valve heater fitting.
(See 01-16-10 POSITIVE CRANKCASE
VENTILATION (PCV) VALVE INSPECTION
[MZI-3.5].) 01-02
(See 01-16-13 POSITIVE CRANKCASE
VENTILATION (PCV) VALVE HEATER
FITTING INSPECTION [MZI-3.5].)
• Is there any malfunction?
10 VERIFY TROUBLESHOOTING OF DTC P053A Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–153
1890-1U-06H(01-02).fm 154 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0579 [MZI-3.5]
id0102d1870500

DTC P0579 Cruise control multi-function input circuit range/performance

DETECTION
• P0579 may set when the cruise control switch circuits are open, shorted to voltage or ground.
CONDITION
• Connector or terminal malfunction
• Open circuit between cruise control switch terminal B and PCM terminal 1AT
• Open circuit between cruise control switch terminal C and PCM terminal 1AP
• Short to power supply between cruise control switch terminal B and PCM terminal 1AT
POSSIBLE
• Short to power supply between cruise control switch terminal C and PCM terminal 1AP
CAUSE
• Short to ground circuit between cruise control switch terminal B and PCM terminal 1AT
• Short to ground circuit between cruise control switch terminal C and PCM terminal 1AP
• Cruise control switch malfunction
• PCM malfunction
CRUISE CONTROL SWITCH PCM

8
3 4 5 7 6
B 1AT

3 4 5 7 6
C 1AP

PCM
WIRING HARNESS-SIDE CONNECTOR
CRUISE CONTROL SWITCH
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C
H G F E D C B A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT CRUISE CONTROL SWITCH Yes Repair or replace suspected part, then go to Step 9.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch to off.
• Disconnect the cruise control switch connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–154
1890-1U-06H(01-02).fm 155 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 IINSPECT CRUISE CONTROL SWITCH CIRCUIT Yes Repair or replace suspected part, then go to Step 9.
FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals:
— Cruise control switch terminal B and body 01-02
ground
— Cruise control switch terminal C and body
ground
• Are there voltage B+?
5 INSPECT CRUISE CONTROL SWITCH CIRCUIT Yes Repair or replace suspected part, then go to Step 9.
FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between the following
terminals:
— Cruise control switch terminal B and body
ground
— Cruise control switch terminal C and body
ground
• Are there continuity?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next Step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
7 INSPECT CRUISE CONTROL SWITCH CIRCUIT Yes Go to the next step.
FOR OPEN No Repair or replace suspected part, then go to Step 9.
• Disconnect the PCM connector.
• Inspect for continuity between the following
terminals:
— Cruise control switch terminal B and PCM
terminal 1AT
— Cruise control switch terminal C and PCM
terminal 1AP
• Are there continuity?
8 INSPECT CRUISE CONTROL SWITCH Yes Replace the cruise control switch, then go to the next step.
• Inspect the cruise control switch. No Go to the next step.
(See 01-20-1 CRUISE CONTROL SWITCH
INSPECTION [MZI-3.5].)
• Is there malfunction?
9 VERIFY TROUBLESHOOTING OF DTC P0579 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–155
1890-1U-06H(01-02).fm 156 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0581 [MZI-3.5]
id0102d1870600

DTC P0581 Cruise control multi-function input circuit high

DETECTION
• P0581 sets when the cruise control switch circuits are shorted to voltage or open.
CONDITION
• Connector or terminal malfunction
• Open circuit between cruise control switch terminal B and PCM terminal 1AT
• Open circuit between cruise control switch terminal C and PCM terminal 1AP
POSSIBLE
• Short to power supply between cruise control switch terminal B and PCM terminal 1AT
CAUSE
• Short to power supply between cruise control switch terminal C and PCM terminal 1AP
• Cruise control switch malfunction
• PCM malfunction
CRUISE CONTROL SWITCH PCM

7
3 4 6 5
B 1AT

3 4 6 5
C 1AP

PCM
WIRING HARNESS-SIDE CONNECTOR
CRUISE CONTROL SWITCH
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C
H G F E D C B A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT CRUISE CONTROL SWITCH Yes Repair or replace suspected part, then go to Step 8.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch to off.
• Disconnect the cruise control switch connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–156
1890-1U-06H(01-02).fm 157 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 IINSPECT CRUISE CONTROL SWITCH CIRCUIT Yes Repair or replace suspected part, then go to Step 8.
FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals:
— Cruise control switch terminal B and body 01-02
ground
— Cruise control switch terminal C and body
ground
• Are there voltage B+?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT CRUISE CONTROL SWITCH CIRCUIT Yes Go to the next step.
FOR OPEN No Repair or replace suspected part, then go to Step 8.
• Disconnect the PCM connector.
• Inspect for continuity between the following
terminals:
— Cruise control switch terminal B and PCM
terminal 1AT
— Cruise control switch terminal C and PCM
terminal 1AP
• Is there continuity?
7 INSPECT CRUISE CONTROL SWITCH Yes Replace the cruise control switch, then go to the next step.
• Inspect the cruise control switch. No Go to the next step.
(See 01-20-1 CRUISE CONTROL SWITCH
INSPECTION [MZI-3.5].)
• Is there malfunction?
8 VERIFY TROUBLESHOOTING OF DTC P0581 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
SOKYU_WM: DTC P06XX

01-02–157
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0600 [MZI-3.5]
id0102d1870700

DTC P0600 Serial communication link

DETECTION
• Indicates an error occurred in the PCM. This DTC may be set alone or in combination with P2105.
CONDITION
POSSIBLE
• PCM malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
4 VERIFY TROUBLESHOOTING OF DTC P0600 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO and KOER self-test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–158
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0602 [MZI-3.5]
id0102d1809200

DTC P0602 PCM programming error

DETECTION
• This DTC indicates a programming error within the vehicle ID block.
CONDITION
POSSIBLE
• Vehicle ID data corrupted by the M-MDS during vehicle ID reprogramming
CAUSE
01-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Reprogram the vehicle ID using the M-MDS, then go to the
• Is any related Service Bulletins available? next step.
3 VERIFY TROUBLESHOOTING OF DTC P0602 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P06XX

01-02–159
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0603 [MZI-3.5]
id0102d1821500

DTC P0603 PCM keep alive memory (KAM) error

DETECTION • Indicates the PCM has experienced an internal memory concern. However, there are external items that
CONDITION can cause this DTC.
• Reprogramming
• Battery terminal corrosion
POSSIBLE
• Open circuit between battery positive terminal and PCM terminal 1BB
CAUSE
• Connector or terminal malfunction
• Loose battery connection
PCM

5 4
1BB
3 3
- +

BATTERY

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

01-02–160
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ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins and/or on-line • If vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any Service Bulletins available?
3 INSPECT BATTERY TERMINALS FOR POOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Inspect for poor connection and corrosion.
• Are there any malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
5 INSPECT MONITOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 7.
• Turn the ignition switch off.
• Disconnect the battery cables.
• Disconnect the PCM connector.
• Inspect the continuity between battery positive
terminal (wiring harness-side) and PCM
terminal 1BB (wiring harness-side).
• Is there continuity?
6 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY TROUBLESHOOTING OF DTC P0603 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PRECAUTION”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
SOKYU_WM: DTC P06XX

01-02–161
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0604 [MZI-3.5]
id0102d1809300

DTC P0604 Internal control module random access memory (RAM) error
DETECTION
• Indicates the PCM RAM has been corrupted.
CONDITION
• Module reprogramming
POSSIBLE
• Aftermarket performance products.
CAUSE
• PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Perform PCM reprograming using the M-MDS, then go to
• Is any related Service Bulletins available? next step.
3 VERIFY TROUBLESHOOTING OF P0604 HAS Yes Replace the PCM, go to the next step.
BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P0605 [MZI-3.5]
WM: DTC P06XX

id0102d1821600

DTC P0605 PCM read only memory (ROM) error

DETECTION
• The PCM ROM has been corrupted.
CONDITION
• An attempt was made to change the calibration
POSSIBLE
• Module programming error
CAUSE
• PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins and/or on-line • If vehicle is not repaired, go to next step.
repair information availability. No Perform PCM reprograming using the M-MDS, then go to
• Is any related Service Bulletins available? next step.

01-02–162
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 VERIFY TROUBLESHOOTING OF DTC P0605 Yes Replace the PCM, then go to next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using 01-02
the M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PRECAUTION”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P0606 [MZI-3.5]
SOKYU_WM: DTC P06XX

id0102d1809400

DTC P0606 ECM/PCM processor

DETECTION
• This DTC indicates a register hardback (PCM internal communications) error.
CONDITION
POSSIBLE
• PCM malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Perform PCM reprograming using the M-MDS, then go to
• Is any related Service Bulletins available? next step.
3 VERIFY TROUBLESHOOTING OF P0606 HAS Yes Replace the PCM, go to the next step.
BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–163
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0607 [MZI-3.5]
id0102d1809500

DTC P0607 Control module performance

DETECTION • Indicates that the PCM internal CPU has encountered an error. The PCM monitors itself and carries out
CONDITION internal checks of its own CPU. If any of these checks returns an incorrect value, the DTC is set.
POSSIBLE
• PCM malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Perform PCM reprograming using the M-MDS, then go to
• Is any related Service Bulletins available? next step.
3 VERIFY TROUBLESHOOTING OF DTC P0607 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P060A, P060C, P061D [MZI-3.5]
WM: DTC P06XX

id0102d1881200

DTC P060A P060A: Internal control module monitoring processor performance

DTC P060C P060C: Internal control module main processor performance
DTC P061D P061D: Internal control module engine air mass performance
DETECTION • Indicates an error occurred in the PCM.
CONDITION
POSSIBLE • Software incompatibility issue
CAUSE • PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair
• Has FREEZE FRAME DATA been recorded? order, then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the
AVAILABILITY available Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next
repair information availability. step.
• Is any related Service Bulletins available? No Go to the next step.

01-02–164
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT PCM FOR LATEST CALIBRATION Yes Go to the next step.
• Program the PCM to the latest calibration. No Go to Step 5.
• Turn the ignition switch off.
• Perform the KOEO self-test.
• Turn the ignition switch off.
• Perform the KOER self-test.
• Use the customer information to recreate the 01-02
concern.
• Perform the self-test.
• Are DTCs P060A, P060C or P060D present?
4 INSPECT FOR CORRECT PCM OPERATION Yes Replace the PCM, then go to the next step.
• Disconnect all the PCM connectors. (See 01-40-4 PCM REMOVAL/INSTALLATION
• Visually inspect for: [MZI-3.5].)
— Pushed out pins No Go to the next step.
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
5 VERIFY TROUBLESHOOTING OF MISFIRE DTC Yes Replace the PCM, then go to the next step.
P060A, P060C AND P061D HAS BEEN (See 01-40-4 PCM REMOVAL/INSTALLATION
COMPLETED [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using the
M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P060B [MZI-3.5]
id0102d1881300

DTC P060B Internal control module A/D processing performance

DETECTION • Indicates that an error occurred in the PCM.
CONDITION
POSSIBLE • PCM malfunction
CAUSE

STEP INSPECTION ACTION

1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR STORED Yes Go to the appropriate DTC troubleshooting.
DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON position No Go to the next step.
(Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?

01-02–165
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT FOR REFERENCE VOLTAGE CONCERNS Yes Go to the next step.
• Inspect the PCM wiring harness for damage. No Go to Step 6.
• Verify the correct operation of the sensors using
ETCREF, VREF and related circuits.
• Is a concern present?
5 INSPECT FOR CORRECT PCM OPERATION Yes Replace the PCM, then go to the next step.
• Disconnect all the PCM connectors. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Visually inspect for: 3.5].)
— Pushed out pins No Go to the next step.
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY TROUBLESHOOTING OF DTC P060B HAS Yes Replace the PCM, then go to the next step.
BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using the M-
MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE [MZI- No Troubleshooting completed.
3.5].)
• Are any DTC present?

End Of Sie
DTC P0610 [MZI-3.5]
SOKYU_WM: DTC P06XX

id0102d1809600

DTC P0610 Control module vehicle options error

DETECTION
• Indicates a PCM vehicle options error.
CONDITION
• Module reprogramming
POSSIBLE
• Aftermarket performance products.
CAUSE
• PCM malfunction.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Perform PCM reprograming using the M-MDS, then go to
• Is any related Service Bulletins available? next step.
3 VERIFY TROUBLESHOOTING OF DTC P0610 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?

01-02–166
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie 01-02

DTC P061B [MZI-3.5]
WM: DTC P06XX

id0102d1877300

DTC P061B Internal control module torque calculation performance

DETECTION • Indicates that a calculation error occurred in the PCM.
CONDITION
POSSIBLE • Connector or terminal malfunction
CAUSE
Note
• This DTC is an informational DTC and may be set in combination with a number of other DTCs which
are causing the FMEM. Diagnose other DTCs first.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR STORED Yes Go to the appropriate DTC troubleshooting.
DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON position No Go to the next step.
(Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 INSPECT FOR CORRECT PCM OPERATION Yes Replace the PCM, then go to the next step.
• Disconnect all the PCM connectors. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Visually inspect for: 3.5].)
— Pushed out pins No Go to the next step.
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
5 VERIFY TROUBLESHOOTING OF DTC P061B HAS Yes Replace the PCM, then go to the next step.
BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors are 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using the M-
MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–167
1890-1U-06H(01-02).fm 168 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P061C [MZI-3.5]
id0102d1881500

DTC P061C Internal control module engine RPM performance

DETECTION • Indicates that a calculation error occurred in the PCM.
CONDITION
• CKP sensor circuit is open or short.
• CKP sensor circuit intermittent
• CKP sensor malfunction
POSSIBLE
• CMP sensor circuit is open or short.
CAUSE
• CMP sensor circuit intermittent
• CMP sensor malfunction
• PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair
• Has FREEZE FRAME DATA been recorded? order, then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the
AVAILABILITY available Service Bulletins.
• Verify related Service Bulletins and/or on-line repair • If the vehicle is not repaired, go to the next
information availability. step.
• Is any related Service Bulletins available? No Go to the next step.
3 VERIFY RELATED PENDING CODE OR STORED Yes Go to the appropriate DTC troubleshooting.
DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON position No Go to the next step.
(Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
4 INSPECT CKP SENSOR SIGNAL SENT TO PCM Yes Go to the next step.
No Inspect the CKP sensor or related harness.
Note Repair or replace suspected part, then go to the
• The battery should be fully charged and the next step.
starting system should be functioning properly.

• Disable the inertia switch.

• Perform the KOEO self-test.
• Access the PCM and monitor the RPM PID.
• Crank the engine.
• Is the RPM greater than 150 rpm?
5 INSPECT FOR CORRECT PCM OPERATION Yes Replace the PCM, then go to the next step.
• Disconnect all the PCM connectors. (See 01-40-4 PCM REMOVAL/INSTALLATION
• Visually inspect for: [MZI-3.5].)
— Pushed out pins No Go to the next step.
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY TROUBLESHOOTING OF DTC P061C HAS Yes Replace the PCM, then go to the next step.
BEEN COMPLETED (See01-40-4 PCM REMOVAL/INSTALLATION
• Verify that all disconnected connectors are [MZI-3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using the M-
MDS.
• Perform the “KOEO and KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-3.5].)
• Retrieve the DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE [MZI- No Troubleshooting completed.
3.5].)
• Are any DTCs present?

01-02–168
1890-1U-06H(01-02).fm 169 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

End Of Sie

DTC P061F [MZI-3.5]

id0102d1883000

DTC P061F Internal control module throttle actuator controller performance

DETECTION • Indicates that a calculation error occurred in the PCM.
CONDITION
POSSIBLE Note
CAUSE • This DTC is an informational DTC and may be set in combination with a number of other DTCs which
are causing the FMEM. Diagnose other DTCs first. 01-02

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR STORED Yes Go to the appropriate DTC troubleshooting.
DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON position No Go to the next step.
(Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
4 INSPECT FOR CORRECT PCM OPERATION Yes Replace the PCM, then go to the next step.
• Disconnect all the PCM connectors. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Visually inspect for: 3.5].)
— Pushed out pins No Go to the next step.
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
5 VERIFY TROUBLESHOOTING OF DTC P061F HAS Yes Replace the PCM, then go to the next step.
BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors are 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using the M-
MDS.
• Perform the KOEO and KOER self-test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–169
1890-1U-06H(01-02).fm 170 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0620 [MZI-3.5]
id0102d1833200

DTC P0620 Generator control circuit

DETECTION • The PCM reads the generator and sends a DTC through the network when the generator indicates a
CONDITION concern.
• Drive belt misadjustment
• Generator malfunction
• Open circuit between generator terminal LI and PCM terminal 2AG
POSSIBLE • Open circuit between generator terminal B and battery positive terminal
CAUSE • Short to ground between generator terminal LI and PCM terminal 2AG
• Short to power supply between generator terminal LI and PCM terminal 2AG
• Connector or terminal malfunction
• PCM malfunction
GENERATOR PCM

4 5 6 8 7
11
LI 2AG GENERATOR LOAD INPUT

4 7
RC 2S GENERATOR REGULATOR CONTROL

4
A

4 10
B
9
- +

BATTERY

PCM
WIRING HARNESS-SIDE CONNECTOR
GENERATOR
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

B A RC LI
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT DRIVE BELT CONDITION Yes Go to the next step.
• Verify that drive belt auto tensioner indicator No Replace and/or adjust drive belt, then go to Step 12.
mark does not exceed limit. (See 01-10-4 DRIVE BELT INSPECTION [MZI-3.5].)
• Is drive belt normal?

01-02–170
1890-1U-06H(01-02).fm 171 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT GENERATOR TERMINAL FOR POOR Yes Connect generator terminal B correctly, then go to Step 12.
INSTALLATION No Go to the next step.
• Turn the engine switch off.
• Inspect generator terminal B for looseness.
• Are there any malfunction?
5 INSPECT GENERATOR CIRCUIT FOR SHORT Yes Repair or replace suspected part, then go to Step 12.
TO POWER SUPPLY No Go to the next step. 01-02
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between generator terminal LI
(wiring harness-side) and body ground.
• Is voltage B+?
6 INSPECT GENERATOR CIRCUIT FOR SHORT Yes Repair or replace suspected part, then go to the next step.
TO GROUND No Go to the next step.
• Inspect for continuity between generator
terminal LI (wiring harness-side) and body
ground.
• Is there continuity?
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 12.
CONNECTION No Go to the next step.
• Turn the engine switch off.
• Inspect for poor connection (such as damaged/
pulled-out terminals, corrosion).
• Are there any malfunction?
8 INSPECT GENERATOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 12.
• Inspect for continuity between generator
terminal LI (wiring harness-side) and PCM
terminal 2AG (wiring harness-side)
• Is there continuity?
9 INSPECT BATTERY POSITIVE TERMINAL FOR Yes Connect the battery positive terminal correctly, then go to
POOR INSTALLATION Step 12.
• Turn the engine switch off. No Go to the next step.
• Inspect the battery positive terminal for
looseness.
• Is there any malfunction?
10 INSPECT GENERATOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 12.
• Inspect continuity between generator terminal
B (wiring harness-side) and battery positive
terminal (wiring harness-side).
• Is there continuity?
11 INSPECT GENERATOR Yes Replace the generator, then go to the next step.
• Inspect the generator. (See 01-17-4 GENERATOR REMOVAL/INSTALLATION
(See 01-17-5 GENERATOR INSPECTION [MZI-3.5].)
[MZI-3.5].) No Go to the next step.
• Is there any malfunction?
12 VERIFY TROUBLESHOOTING OF DTC P0620 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
13 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
01-02–171
1890-1U-06H(01-02).fm 172 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0625 [MZI-3.5]
SOKYU_WM: DTC P06XX

id0102d1870900

DTC P0625
Generator field terminal circuit low
• The PCM monitors generator load from the generator/regulator in the form of frequency. The concern
DETECTION
indicates the input is lower than the load should be in normal operation. The load input could be low when
CONDITION
no generator output exists.
• Drive belt damaged
• Generator malfunction
• Short to ground between generator terminal RC and PCM terminal 2S
POSSIBLE
• Short to ground between generator terminal LI and PCM terminal 2AG
CAUSE
• Open circuit between terminal B and battery positive terminal
• Low system voltage
• Connector or terminal malfunction
GENERATOR PCM

4 5 8
9
LI 2AG GENERATOR LOAD INPUT

4 5 8
RC 2S GENERATOR REGULATOR CONTROL

4
A

4 7
B
6
- +

BATTERY

PCM
WIRING HARNESS-SIDE CONNECTOR
GENERATOR
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

B A RC LI
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT DRIVE BELT DAMAGED Yes Go to the next step.
• Verify inspect the drive belt for damage. No Replace the drive belt, then go to Step 10.
• Is the drive belt normal? (See 01-10-4 DRIVE BELT INSPECTION [MZI-3.5].)

01-02–172
1890-1U-06H(01-02).fm 173 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT GENERATOR TERMINAL FOR POOR Yes Connect generator terminal B correctly, then go to Step 10.
INSTALLATION No Go to the next step.
• Turn the engine switch off.
• Inspect generator terminal B for looseness.
• Are there any malfunction?
5 INSPECT GENERATOR CIRCUIT FOR SHORT Yes Repair or replace suspected part, then go to Step 10.
TO GROUND No Go to the next step. 01-02
• Inspect for continuity between the following
terminal:
— Generator terminal RC (wiring
harness-side) and body ground.
— Generator terminal LI (wiring harness-side)
and body ground.
• Are there continuity?
6 INSPECT BATTERY POSITIVE TERMINAL FOR Yes Connect the battery positive terminal correctly, then go to
POOR INSTALLATION Step 10.
• Turn the engine switch off. No Go to the next step.
• Inspect the battery positive terminal for
looseness.
• Is there any malfunction?
7 INSPECT GENERATOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Inspect the continuity between generator
terminal B (wiring harness-side) and battery
positive terminal (wiring harness-side)
• Is there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the engine switch off.
• Inspect for poor connection (such as damaged/
pulled-out terminals, corrosion).
• Are there any malfunction?
9 INSPECT GENERATOR Yes Replace the generator, then go to Step 10.
• Inspect the generator. (See 01-17-4 GENERATOR REMOVAL/INSTALLATION
(See 01-17-5 GENERATOR INSPECTION [MZI-3.5].)
[MZI-3.5].) No Go to the next step.
• Is there any malfunction?
10 VERIFY TROUBLESHOOTING OF DTC P0625 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–173
1890-1U-06H(01-02).fm 174 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0626 [MZI-3.5]
id0102d1872000

DTC P0626 Generator field terminal circuit high

• The PCM monitors generator load from the generator/regulator in the form of frequency. The concern
DETECTION
indicates the input is higher than the load should be in normal operation. The load input could be high when
CONDITION
a battery short to ground exists.
• Open circuit in wiring harness between generator terminal RC and PCM terminal 2S
POSSIBLE • Short to power supply between generator terminal RC and PCM terminal 2S
CAUSE • Short to power supply between generator terminal LI and PCM terminal 2AG
• Connector or terminal malfunction
GENERATOR PCM

3 4 5
LI 2AG GENERATOR LOAD INPUT

3 4 6 5
RC 2S GENERATOR REGULATOR CONTROL

3
A

3 8
B
7
- +

BATTERY

PCM
WIRING HARNESS-SIDE CONNECTOR
GENERATOR
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

B A RC LI
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT GENERATOR TERMINAL FOR POOR Yes Connect generator terminal B correctly, then go to Step 9.
INSTALLATION No Go to the next step.
• Turn the engine switch off.
• Inspect generator terminal B for looseness.
• Are there any malfunction?

01-02–174
1890-1U-06H(01-02).fm 175 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT GENERATOR CIRCUIT FOR SHORT Yes Repair or replace suspected part, then go to Step 9.
TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals:
— Generator terminal RC (wiring harness- 01-02
side) and body ground.
— Generator terminal LI (wiring harness-side)
and body ground.
• Is the voltage B+?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the engine switch off.
• Inspect for poor connection (such as damaged/
pulled-out terminals, corrosion).
• Are there any malfunction?
6 INSPECT GENERATOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Inspect for continuity between generator
terminal RC (wiring harness-side) and PCM
terminal 2S (wiring harness-side).
• Is there continuity?
7 INSPECT BATTERY POSITIVE TERMINAL FOR Yes Connect the battery positive terminal correctly, then go to
POOR INSTALLATION Step 9.
• Turn the engine switch off. No Go to the next step.
• Inspect the battery positive terminal for
looseness.
• Is there any malfunction?
8 INSPECT GENERATOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to the next step.
• Inspect the continuity between generator
terminal B (wiring harness-side) and battery
positive terminal (wiring harness-side)
• Is there continuity?
9 VERIFY TROUBLESHOOTING OF DTC P0626 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO or KOER self-test using the
M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P06XX

01-02–175
1890-1U-06H(01-02).fm 176 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0642 [MZI-3.5]
id0102d1955400

DTC P0642 Sensor reference voltage circuit low

DETECTION
• Indicates the reference voltage circuit is lower than reference voltage minimum.
CONDITION
• Short to ground between fuel tank pressure sensor terminal C and PCM terminal 1U
POSSIBLE
• Fuel tank pressure sensor malfunction
CAUSE
• Connector or terminal malfunction
FUEL TANK PRESSURE SENSOR PCM

6
3 5 4
C 1U

3 4
A 1AB

3 4
B 1AL

PCM
WIRING HARNESS-SIDE CONNECTOR
FUEL TANK PRESSURE SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

C B A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

01-02–176
1890-1U-06H(01-02).fm 177 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT FUEL TANK PRESSURE SENSOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel tank pressure sensor
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
5 INSPECT FUEL TANK PRESSURE SENSOR Yes Repair or replace suspected part, then go to Step 7.
CIRCUIT FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect the continuity between fuel tank
pressure sensor terminal C (wiring harness-
side) and body ground.
• Is there continuity?
6 INSPECT FUEL TANK PRESSURE SENSOR Yes Replace the evaporative hose component, then go to the
• Inspect the fuel tank pressure sensor. next step.
(See 01-40-30 FUEL TANK PRESSURE (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-
SENSOR INSPECTION [MZI-3.5].) 3.5].)
• Is there any malfunction? No Go to the next step.
7 VERIFY TROUBLESHOOTING OF DTC P0642 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–177
1890-1U-06H(01-02).fm 178 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0643 [MZI-3.5]
id0102d1955500

DTC P0643 Sensor reference voltage circuit high

DETECTION
• Indicates the reference voltage circuit is higher than reference voltage maximum.
CONDITION
• Short to power supply between fuel tank pressure sensor terminal C and PCM terminal 1U
POSSIBLE
• Fuel tank pressure sensor malfunction
CAUSE
• Connector or terminal malfunction
FUEL TANK PRESSURE SENSOR PCM

6
3 5 4
C 1U

3 4
A 1AB

3 4
B 1AL

PCM
WIRING HARNESS-SIDE CONNECTOR
FUEL TANK PRESSURE SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

C B A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

01-02–178
1890-1U-06H(01-02).fm 179 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT FUEL TANK PRESSURE SENSOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel tank pressure sensor
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
5 INSPECT FUEL TANK PRESSURE SENSOR Yes Repair or replace suspected part, then go to Step 7.
CIRCUIT FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage continuity between fuel
tank pressure sensor terminal C (wiring
harness-side) and body ground.
• Is the voltage B+?
6 INSPECT FUEL TANK PRESSURE SENSOR Yes Replace the evaporative hose component, then go to the
• Inspect the fuel tank pressure sensor. next step.
(See 01-40-30 FUEL TANK PRESSURE (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-
SENSOR INSPECTION [MZI-3.5].) 3.5].)
• Is there any malfunction? No Go to the next step.
7 VERIFY TROUBLESHOOTING OF DTC P0643 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–179
1890-1U-06H(01-02).fm 180 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0645 [MZI-3.5]
id0102d1833500

DTC P0645 A/C relay control circuit

• Monitors the A/C relay control circuit output from the PCM. The test fails when the PCM grounds the A/C
DETECTION relay control circuit, excessive current draw is detected on the A/C relay control circuit; or, with the A/C relay
CONDITION control circuit not grounded by the PCM, voltage is not detected on the A/C relay control circuit (the PCM
expects to detect vehicle power voltage coming through the A/C relay coil to the A/C circuit).
• A/C relay malfunction
• Connector or terminal malfunction
POSSIBLE • Open circuit in wiring between main relay terminal No.1 D and A/C relay terminal A
CAUSE • Open circuit in wiring between A/C relay terminal E and PCM terminal 1N
• Short to ground in wiring between A/C relay terminal E and PCM terminal 1N
• Short to power supply between A/C relay terminal E and PCM terminal 1N
BATTERY MAIN RELAY NO.1

5
4 4

C A

A/C RELAY 10

PCM
D E

4 4

6 7 9 8 11
1N
TO MAGNETIC CLUTCH

PCM
WIRING HARNESS-SIDE CONNECTOR
MAIN RELAY NO.1 A/C RELAY

A E A E 1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C
C C

D D 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.

01-02–180
1890-1U-06H(01-02).fm 181 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT THAT THE ACCS PID IS OFF Yes Go to the next step.
• Turn ignition key to ON (Engine running). No ACCS input to PCM is requesting A/C. Inspect A/C system 01-02
• A/C switch and defroster switch off. operation, then go to Step 12.
• Access the ACCS PID uesing M-MDS. (See 07-02-3 DIAGNOSTIC TROUBLE CODE NUMBER
• Is the PID state off? INSPECTION.)
(See 07-03-4 TROUBLESHOOTING INDEX.)
4 INSPECT A/C RELAY CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 12.
CONNECTOR No Go to the next step.
• Turn the ignition switch off.
• Disconnect the A/C relay connector.
• Inspect for poor connection (such as damaged,
pulled-out pins, corrosion, etc.).
• Are there any malfunction?
5 INSPECT A/C RELAY POWER SUPPLY CIRCUIT Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 12.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between A/C relay terminal A
(wiring harness-side) and body ground.
• Is voltage B+?
6 INSPECT A/C RELAY CONTROL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 12.
SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Remove the A/C relay.
• Measure voltage between A/C relay terminal E
(wiring harness-side) and body ground.
• Is voltage B+?
7 INSPECT A/C RELAY CONTROL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 12.
SHORT TO GROUND No Go to the next step.
• Install the A/C relay.
• Turn the ignition switch off.
• Inspect continuity between A/C relay terminal E
(wiring harness-side) and body ground.
• Is there continuity?
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 12.
CONNECTION No Go to the next step.
• Turn ignition switch to off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged,
pulled-out pins, corrosion).
• Is there any malfunction?
9 INSPECT A/C RELAY CONTROL CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 12.
• Turn the ignition switch off.
• Inspect continuity between A/C relay terminal E
(wiring harness-side) and PCM terminal 1N
(wiring harness-side).
• Is there continuity?
10 INSPECT A/C RELAY Yes Go to the next step.
• Inspect A/C relay. No Replace the A/C relay. Start the engine. Turn on the A/C
(See 09-21-6 RELAY INSPECTION.) switch. Wait for 15 s. Turn off the A/C switch, then go to
• Is A/C relay normal? Step 12.

01-02–181
1890-1U-06H(01-02).fm 182 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
11 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
12 VERIFY TROUBLESHOOTING OF DTC P0645 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
13 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–182
1890-1U-06H(01-02).fm 183 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0685 [MZI-3.5]
id0102d1956100

DTC P0685 ECM/PCM power relay control circuit/open

• This DTC sets when the ignition switch position run circuit indicates the key is in the off, ACC, or LOCK
DETECTION
position, and the amount of time the PCM remains powered through the PCM power relay exceeds a
CONDITION
predetermined amount of time.
• Short to ground circuit between main relay No.1 terminal A and PCM terminal 1BM
POSSIBLE
• Main relay No.1 malfunction 01-02
CAUSE
• PCM malfunction
BATTERY

C E

MAIN RELAY NO.1

PCM
D A

3 4
1BM
TO MAIN RELAY NO.2

PCM
WIRING HARNESS-SIDE CONNECTOR
MAIN RELAY NO.1

A E 1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C
C

D 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–183
1890-1U-06H(01-02).fm 184 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT MAIN RELAY NO.1 CONTROL Yes Repair or replace suspected part, then go to Step 5.
CIRCUIT FOR SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between main relay No.1
terminal A (wiring harness-side) and body
ground.
• Is there continuity?
4 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
5 VERIFY TROUBLESHOOTING OF DTC P0685 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
SOKYU_WM: DTC P06XX

01-02–184
1890-1U-06H(01-02).fm 185 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0689 [MZI-3.5]
id0102d1872200

DTC P0689 ECM/PCM power relay sense circuit low

DETECTION • This DTC sets when the passive anti theft system (PATS) system indicates the key is in ON or START
CONDITION position and the ignition switch position run circuit indicates OFF, ACC, or LOCK position.
• Ignition circuit fuse (MAIN, IG KEY 1, IG KEY 2)
• Open circuit between battery positive terminal and PCM terminal 1BD
POSSIBLE
• Short to ground circuit between battery positive terminal and PCM terminal 1BD 01-02
CAUSE
• Ignition switch malfunction
• PATS system malfunction
PCM

IGNITION SWITCH
5 4 6
1BD

- +

BATTERY

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT ALL OTHER PATS DTCs Yes Go to the next step.
• Repair all other PATS DTCs before P0689. No (See 09-14-19 IMMOBILIZER SYSTEM COMPONENT
(See 09-14-19 IMMOBILIZER SYSTEM REPLACEMENT/KEY ADDITION AND CLEARING
COMPONENT REPLACEMENT/KEY [ADVANCED KEYLESS SYSTEM].)
ADDITION AND CLEARING [ADVANCED (See 09-14-37 IMMOBILIZER SYSTEM COMPONENT
KEYLESS SYSTEM].) REPLACEMENT/KEY ADDITION AND CLEARING
(See 09-14-37 IMMOBILIZER SYSTEM [KEYLESS ENTRY SYSTEM].)
COMPONENT REPLACEMENT/KEY
ADDITION AND CLEARING [KEYLESS
ENTRY SYSTEM].)
• Have all other PATS DTCs been diagnosed?

01-02–185
1890-1U-06H(01-02).fm 186 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged,
pulled-out pins, corrosion).
• Is there any malfunction?
5 INSPECT BATTERY POSITIVE CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 7.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between PCM terminal
1BD (wiring harness-side) and body ground.
• Is the voltage B+?
6 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY TROUBLESHOOTING OF DTC P0689 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–186
1890-1U-06H(01-02).fm 187 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P0690 [MZI-3.5]
id0102d1872300

DTC P0690 ECM/PCM power relay sense circuit high

DETECTION • This DTC sets when the passive anti theft system (PATS) system indicates the key is in the OFF, ACC, or
CONDITION LOCK position and the ignition switch position run circuit indicates ON or START position.
• Short to power supply between battery positive terminal and PCM terminal 1BD
POSSIBLE
• PATS system malfunction
CAUSE
• Ignition switch malfunction 01-02
PCM

IGNITION SWITCH
4 5
1BD

- +

BATTERY

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT ALL OTHER PATS DTCs Yes Go to the next step.
• Repair all other PATS DTCs before P0690. No (See 09-14-19 IMMOBILIZER SYSTEM COMPONENT
(See 09-14-19 IMMOBILIZER SYSTEM REPLACEMENT/KEY ADDITION AND CLEARING
COMPONENT REPLACEMENT/KEY [ADVANCED KEYLESS SYSTEM].)
ADDITION AND CLEARING [ADVANCED (See 09-14-37 IMMOBILIZER SYSTEM COMPONENT
KEYLESS SYSTEM].) REPLACEMENT/KEY ADDITION AND CLEARING
(See 09-14-37 IMMOBILIZER SYSTEM [KEYLESS ENTRY SYSTEM].)
COMPONENT REPLACEMENT/KEY
ADDITION AND CLEARING [KEYLESS
ENTRY SYSTEM].)
• Have all other PATS DTCs been diagnosed?

01-02–187
1890-1U-06H(01-02).fm 188 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT IGNITION SWITCH POSITION RUN Yes Repair or replace suspected part, then go to Step 6.
CIRCUIT SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch off.
• Measure the voltage between PCM terminal
1BD (wiring harness-side) and body ground.
• Is the voltage B+?
5 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY TROUBLESHOOTING OF DTC P0690 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P10XX

01-02–188
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1000 [MZI-3.5]
id0102d1821900

DTC P1000 OBD-II systems readiness test not complete

DETECTION
• P1000 indicates that the OBD-II monitor testing is not complete.
CONDITION
• The vehicle is new from the factory and has not yet completed an OBD-II Drive Cycle.
POSSIBLE • The battery or the PCM has been disconnected.
CAUSE • OBD-II monitor malfunction had occurred before completion of an OBD-II Drive Cycle. 01-02
• The PCM DTCs have been cleared with an M-MDS tester as part of a service process.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 DTC P1000: INSPECT FOR OTHER DTCS Yes Repair other DTCs. Go to the applicable DTC
• This test should be used only if DTC P1000 Troubleshooting.
was received in Continuous Memory. Ignore No Go to the next step.
any DTC P1000s in KOEO or KOER.

Note
• DTC P1000 indicates that all of the OBD-II
monitors have not yet been successfully
tested to clear DTC P1000.

• Were any other DTCs received with P1000?

4 REQUEST TO CLEAR DTC P1000 Yes Perform the Drive Mode.
• Has the customer requested DTC P1000 be (See 01-02-9 OBD-II DRIVE MODE [MZI-3.5].)
cleared from the PCM memory? No Inform customer that if the law in the state requires
additional driving in order to clear DTC P1000 from the
PCM memory, it must be performed before an inspection
maintenance test.
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–189
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1001 [MZI-3.5]
id0102d1822000

DTC P1001
KOER not able to complete, KOER aborted
• P1001 indicates any of the following
• Unable to access Continuous Memory DTCs.
DETECTION • Unable to activate KOEO or KOER Self-Test.
CONDITION • M-MDS tester communication problem.
• DTC displayed by M-MDS tester not listed.
• KOER Self-Test cannot be completed.
• Damaged DLC-2.
• Incorrect Self-Test procedure.
• VREF is not in specification.
POSSIBLE
• Idle RPM out of specification.
CAUSE
• Open in DLC-2 wiring harness circuit.
• Short in DLC-2 circuit or associated modules.
• Damaged PCM power relay circuit

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
4 INSPECT FOR CORRECT PCM OPERATION Yes Replace the PCM, then go to the next step.
• Disconnect all the PCM connectors. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Visually inspect for: No Go to the next step.
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
5 VERIFY TROUBLESHOOTING OF DTC P1001 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
WM: DTC P11XX

01-02–190
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1101 [MZI-3.5]
id0102d1822200

DTC P1101 MAF sensor out of self-test range

• The MAF sensor circuit is monitored by the PCM for an out of range air flow (or voltage) input. If, during
DETECTION KOEO, the air flow voltage signal is more than 0.27 V with the ignition switch in the ON position (Engine
CONDITION off). Likewise, the test fails if the airflow voltage signal is not within 0.46 to 2.44 V with the ignition switch in
the ON position (Engine running) (KOER).
• Low battery charge 01-02
• Open circuit wiring harness between MAF sensor terminal B (wiring harness-side) and body ground
POSSIBLE • Open circuit wiring harness between MAF sensor terminal C (wiring harness-side) and PCM terminal 1AJ
CAUSE (wiring harness-side)
• Connector or terminal malfunction
• MAF sensor malfunction
MAF SENSOR
(MAF/IAT SENSOR) MAIN RELAY NO.1 PCM

5
A

5 7 5
D 1AN MAF SENSOR (+)

8
5 5
C 1AJ MAF SENSOR (-)

5 6
B

PCM
WIRING HARNESS-SIDE CONNECTOR
MAF/IAT SENSOR
MAIN RELAY NO.1 WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
A E 1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

C
F E D C B A 1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
D 1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to next step.
• Is any related Service Bulletins available? No Go to the next step.

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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC inspection.
STORED DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Verify the related PENDING CODE or stored No Go to the next step.
DTCs.
• Are other DTCs present?
4 INSPECT MAF SIGNAL SENT TO PCM Yes Perform the “INTERMITTENT CONCERN
• Turn the ignition switch to the ON position TROUBLESHOOTING”. Then go to Step 10.
(Engine running). No Go to the next step.
• Access MAF PID using the M-MDS
• Is the voltage between 0.46–2.44 V
5 INSPECT MAF SENSOR AND PCM Yes Repair or replace suspected part, then go to Step 10.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor and PCM
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT MAF SENSOR GROUND CIRCUIT Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch off.
• Inspect continuity between MAF sensor
terminal B (wiring harness-side) and body
ground.
• Is there continuity?
7 INSPECT MAF SENSOR SIGNAL CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch off.
• Inspect continuity between MAF sensor
terminal C (wiring harness-side) and PCM
terminal 1AJ (wiring harness-side).
• Is there continuity?
8 INSPECT MAF SENSOR Yes Replace the MAF/IAT sensor, then go to Step 10.
• Inspect the MAF sensor. No Go to the next step.
(See 01-40-9 MASS AIR FLOW (MAF)
SENSOR INSPECTION [MZI-3.5].)
• Is there any malfunction?
9 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
10 VERIFY TROUBLESHOOTING OF DTC P1101 Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear DTC from memory using M-MDS.
• Start engine.
• Perform “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–192
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1127 [MZI-3.5]
id0102d1872400

DTC P1127 Exhaust temperature out of range, HO2S tests not completed
DETECTION • The HO2S monitor uses an exhaust temperature model to determine when the HO2S heaters are cycled
CONDITION ON. The test fails when the inferred exhaust temperature is below a minimum calibrated value.
POSSIBLE • Engine not operating long enough prior to carrying out the KOER self-test
CAUSE • Exhaust system too cool
01-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to next step.
• Is any related Service Bulletins available? No Go to the next step.
3 EXHAUST TEMPERATURE OUT OF RANGE Yes Perform the KOER self-test, then go to the next step.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-3.5].)
Note No Run the engine until the PID indicates ON. Perform the
• Address all other DTCs before proceeding. KOER self-test, then go to the next step.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-3.5].)
• Turn the ignition switch to the ON position
(Engine running)
• Verify that the engine is at normal operating
temperature.
• Access the PCM and monitor the HO2S heater
PID.
• Is the PID state ON?
4 VERIFY TROUBLESHOOTING OF DTC P1127 Yes Replace PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear DTC from memory using M-MDS.
• Start engine.
• Perform “KOEO/KOER self-test”
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–193
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P115E [MZI-3.5]
id0102d1881700

DTC P115E
Throttle actuator control throttle body air flow trim at max limit
• During idle, the PCM monitors the throttle angle and air flow. If the air flow is determined to be less than
DETECTION expected, the PCM adjusts the throttle angle to compensate. The air flow reduction is typically the result of
CONDITION sludge buildup around the throttle plate. This DTC indicates the PCM has reached the maximum allowed
compensation and is no longer able to compensate for the build up.
POSSIBLE • Sludge around the throttle plate
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT FOR OTHER POWERTRAIN DTCs Yes Go to the next step.
• Repair all other powertrain DTCs before P115E. No Go to the appropriate DTC Troubleshooting.
• Have all other powertrain DTCs been
diagnosed?
4 INSPECT THROTTLE BODY Yes Replace the throttle body. Then go to the Step 6.
• Remove the air duct from the throttle valve No Clean the throttle plate and throttle valve body. Then
body. go to the next step.
• Check around the throttle plate for sludge.
• Is the throttle valve normal?
5 PERFORM KOER SELF-TEST Yes Replace the throttle body then go to the step.
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using the
M-MDS.
• Perform the KOER self-test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY TROUBLESHOOTING OF DTC P115E Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using the
M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
WM: DTC P12XX

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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1260 [MZI-3.5]
id0102d1815600

DTC P1260 Theft detected, vehicle immobilized

DETECTION Indicates that the PATS determined a theft condition existed and the engine is disabled. This DTC is a good
CONDITION indicator to check the PATS for DTCs.
POSSIBLE • Previous theft condition
CAUSE • Anti-theft system failure Theft indicator flashing rapidly or on solid when the ignition switch is in the ON
position. 01-02
• Check the anti-theft system for DTCs.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS Yes Go to the next step.
BEEN RECORDED No Record FREEZE FRAME DATA on the repair order, then
• Has FREEZE FRAME DATA been go to the next step.
recorded?
2 VERIFY RELATED REPAIR Yes Perform repair or diagnosis according to the available
INFORMATION AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or • If the vehicle is not repaired, go to the next step.
on-line repair information availability. No Go to the next step.
• Is any related Service Bulletins
available?
3 INSPECT ALL OTHER PATS DTCs Yes Go to the next step.
• Repair all other PATS DTCs before No (See 09-14-19 IMMOBILIZER SYSTEM COMPONENT
P1260. REPLACEMENT/KEY ADDITION AND CLEARING
(See 09-14-19 IMMOBILIZER [ADVANCED KEYLESS SYSTEM].)
SYSTEM COMPONENT (See 09-14-37 IMMOBILIZER SYSTEM COMPONENT
REPLACEMENT/KEY ADDITION AND REPLACEMENT/KEY ADDITION AND CLEARING
CLEARING [ADVANCED KEYLESS [KEYLESS ENTRY SYSTEM].)
SYSTEM].)
(See 09-14-37 IMMOBILIZER
SYSTEM COMPONENT
REPLACEMENT/KEY ADDITION AND
CLEARING [KEYLESS ENTRY
SYSTEM].)
• Have all other PATS DTCs been
diagnosed?
4 INSPECT FOR OTHER POWERTRAIN Yes Go to the next step.
DTCs No Go to the appropriate DTC troubleshooting.
• Repair all other powertrain DTCs
before P1260.
• Have all other powertrain DTCs been
diagnosed?
5 ATTEMPT TO START ENGINE Yes No system malfunctions exists at this time.
• Complete the keep alive memory. For intermittent No Starts or Start Stalls, verify intermittent
• Reset to clear DTC 1260. PATS faults.
• This reset initializes the PCM to Then go to the next step.
communicate with the PATS.
• Attempt to start the engine. Note
• Does the engine start? • PATS cannot stall the engine after 1 second of
operation. For intermittent Stalls while driving, verify
the M-MDS tester to PCM communication during
concern. If a PCM communication error occurs,
possible causes are:
— Loss of PWRS or grounds to the PCM.
— Malfunctioning PCM PWR relay.
— Malfunctioning EEC PWR diode.
• Repair if necessary and return the vehicle to
customer.
No DTC P1260 is not the cause of the No Start.
(See 01-03-5 QUICK DIAGNOSTIC CHART [MZI-3.5].)

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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
6 VERIFY TROUBLESHOOTING OF DTC Yes Replace the PCM, then go to the next step.
P1260 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
are reconnected.
• Turn the ignition switch to the ON
position (Engine off).
• Clear the DTC from the PCM memory
using the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC
present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR (See 01-02-12 DTC TABLE [MZI-3.5].)
PROCEDURE”. No Troubleshooting completed.
(See 01-02-8 AFTER REPAIR
PROCEDURE [MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P1285, P1299 [MZI-3.5]
id0102d1881800

DTC P1285 P1285: Cylinder head over temperature condition

DCT P1299 P1299: Cylinder head over temperature protection active
• P1285 indicates that an engine overheat condition was sensed by the CHT sensor.
DETECTION
• P1299 indicates that an engine overheat condition was detected by the CHT sensor.
CONDITION
• Fail-safe function was activated to cool the engine.
• Low engine coolant level
POSSIBLE • Base engine malfunction
CAUSE • Engine cooling system malfunction
• CHT sensor malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT COOLING SYSTEM Yes Go to the next step.
No Repair if necessary. Then go to the next step.
Warning
• Never remove the cooling system cap or
loosen the radiator drain plug while the
engine is running, or when the engine
and radiator are hot. Scalding engine 01-02
coolant and steam may shoot out and
cause serious injury. It may also damage
the engine and cooling system.
• Turn off the engine and wait until it is
cool. Even then, be very careful when
removing the cap. Wrap a thick cloth
around it and slowly turn it
counterclockwise to the first stop. Step
back while the pressure escapes.
• When you are sure all the pressure is
gone, press down on the cap using the
cloth, turn it, and remove it.

Note
• If the electric cooling fan does not operate,
go to the applicable DTC inspection. (See
01-02-12 DTC TABLE [MZI-3.5].)

• An engine overheat condition is sensed by the

CHT sensor.
• Check the cooling system for:
— Correct coolant level
— Internal or external coolant leaks
— Blockage of the radiator
— Cooling fan operation
• Is the cooling system normal?
4 INSPECT OPERATION OF THE CHT SENSOR Yes Go to the next step.
• Run the engine until the engine temperature No An engine overheat temperature was not detected. Repair
stabilizes. any other DTCs if necessary.
• Verify the radiator hoses are hot and the
cooling system is pressurized.
• Verify self-test DTCs.
• Is DTC P1285 present?
5 INSPECT CHT SENSOR Yes Replace the CHT sensor, then go to the next step.
• Inspect the CHT sensor. No Go to the next step.
(See 01-40-28 CYLINDER HEAD
TEMPERATURE (CHT) SENSOR
INSPECTION [MZI-3.5].)
• Is there any malfunction?
6 VERIFY TROUBLESHOOTING OF DTC P1285, Yes Replace the PCM, then go to the next step.
P1299 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run it at idle.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1288 [MZI-3.5]
id0102d1872600

DTC P1288 CHT sensor out of self-test range

DETECTION
• Indicates the CHT sensor is out of self-test range. The engine is not at a normal operating temperature.
CONDITION
• Cold engine
• Engine overheating
POSSIBLE
• Connector or terminal malfunction
CAUSE
• Low engine coolant level
• CHT sensor malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to next step.
• Is any related Service Bulletins available? No Go to next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC inspection.
STORED DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Verify the related PENDING CODE or stored No Go to the next step.
DTCs.
• Are other DTCs present?
4 INSPECT THE COOLING SYSTEM Yes Go to the next step.
• Inspect the vehicle coolant level. No Inspect the cooling system (overheat), the go to Step 7.
• Is the cooling system normal?
5 INSPECT CHT SENSOR Yes Replace the CHT sensor, then go to Step 7.
• Inspect the CHT sensor. No Go to the next step.
(See 01-40-28 CYLINDER HEAD
TEMPERATURE (CHT) SENSOR
INSPECTION [MZI-3.5].)
• Is there any malfunction?
6 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY TROUBLESHOOTING OF DTC P1288 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO or KOER self-test using the
M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–198
1890-1U-06H(01-02).fm 199 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1289 [MZI-3.5]
id0102d1872700

DTC P1289 CHT sensor circuit high input

DETECTION
• Indicates a CHT sensor circuit open.
CONDITION
• Open circuit in wiring harness between CHT sensor terminal A and PCM terminal 2AL
• Open circuit in wiring harness between CHT sensor terminal B and PCM terminal 2AN
POSSIBLE
• Short to power supply in wiring harness between CHT sensor terminal B and PCM terminal 2AN 01-02
CAUSE
• CHT sensor malfunction
• Connector or terminal malfunction
PCM
CHT SENSOR

3 4 6 5
B 2AN

3 6 5
A 2AL

PCM
CHT SENSOR
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C
A B
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–199
1890-1U-06H(01-02).fm 200 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT POOR CONNECTION OF CHT Yes Repair or replace suspected part, then go to Step 8.
SENSOR CONNECTOR No Go to the next step.
• Turn the ignition switch off.
• Disconnect CHT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT CHT SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 8.
SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between CHT sensor
terminal B (wiring harness-side) and body
ground.
• Is the voltage B+?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT CHT SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Inspect the continuity between the following
circuit:
— CHT sensor terminal A (wiring harness-
side) and PCM terminal 2AL (wiring
harness-side).
— CHT sensor terminal B (wiring harness-
side) and PCM terminal 2AN (wiring
harness-side).
• Are there continuity?
7 INSPECT CHT SENSOR Yes Replace the CHT sensor, then go to the next step.
• Inspect the CHT sensor. No Go to the next step.
(See 01-40-28 CYLINDER HEAD
TEMPERATURE (CHT) SENSOR
INSPECTION [MZI-3.5].)
• Is there any malfunction?
8 VERIFY TROUBLESHOOTING OF DTC P1289 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO or KOER self-test using the
M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–200
1890-1U-06H(01-02).fm 201 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1290 [MZI-3.5]
id0102d1872900

DTC P1290 CHT sensor circuit low input

DETECTION
• Indicates a CHT sensor circuit short to ground.
CONDITION
• Short to ground in wiring harness between CHT sensor terminal B and PCM terminal 2AN
POSSIBLE
• CHT sensor malfunction
CAUSE
• Connector or terminal malfunction 01-02
PCM
CHT SENSOR

3 4
B 2AN

3
A 2AL

PCM
CHT SENSOR
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C
A B
2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT TERMINAL BENT Yes Repair or replace the terminal, then go to Step 6.
• Turn the ignition switch off. No Go to the next step.
• Disconnect the CHT sensor connector.
• Inspect for bent of CHT sensor terminals A and
B (part-side).
• Is there any malfunction?

01-02–201
1890-1U-06H(01-02).fm 202 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT CHT SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 6.
SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between CHT sensor
terminal B (wiring harness-side) and body
ground.
• Is there continuity?
5 INSPECT CHT SENSOR Yes Replace the CHT sensor, then go to the next step.
• Inspect the CHT sensor. No Go to the next step.
(See 01-40-28 CYLINDER HEAD
TEMPERATURE (CHT) SENSOR
INSPECTION [MZI-3.5].)
• Is there any malfunction?
6 VERIFY TROUBLESHOOTING OF DTC P1290 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO or KOER self-test using the
M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P1336 [MZI-3.5]
WM: DTC P13XX

id0102d1824800

DTC P1336 CKP/CMP sensor range/performance

DETECTION
• The input signal to the PCM from the CKP sensor or the CMP sensor is erratic.
CONDITION
• CKP sensor malfunction
POSSIBLE • CMP sensor malfunction
CAUSE • Base engine malfunction
• Connector or terminal malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC inspection.
STORED DTC (See 01-02-12 DTC TABLE [MZI-3.5].)
• Verify the related PENDING CODE or stored No Go to the next step.
DTCs.
• Are other DTCs present?

01-02–202
1890-1U-06H(01-02).fm 203 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT THE CKP SENSOR SIGNAL SENT TO Yes Go to Step 8.
THE PCM No Go to the next step.

Note
• The battery should be fully charged and the
starting system should be functioning
properly. 01-02
• Connect the M-MDS to the DLC-2.
• Access RPM PID.
• Crank the engine.
• Is the reading more than 150 rpm?
5 INSPECT THE FRONT COVER, CKP SENSOR Yes Repair if necessary, then go to Step 11.
AND CKP SENSOR PULSE WHEEL FOR No Go to the next step.
OBVIOUS PHYSICAL DAMAGE
• Turn the ignition switch off.
• Visually inspect the front cover, CKP sensor
and CKP sensor pulse wheel for obvious
physical damage.
• Do any parts appear physically damaged?
6 INSPECT CKP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 11.
POOR CONNECTION No Go to the next step.
• Disconnect the CKP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
7 INSPECT CKP SENSOR Yes Replace the CKP sensor, then go to Step 11.
• Inspect the CKP sensor. (See 01-40-16 CRANKSHAFT POSITION (CKP) SENSOR
(See 01-40-17 CRANKSHAFT POSITION REMOVAL/INSTALLATION [MZI-3.5].)
(CKP) SENSOR INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
8 INSPECT CMP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 11.
POOR CONNECTION No Go to the next step.
• Disconnect the CMP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
9 INSPECT CMP SENSOR Yes Replace the CMP sensor, then go to Step 11.
• Inspect the CMP sensor. (See 01-40-18 CAMSHAFT POSITION (CMP) SENSOR
(See 01-40-18 CAMSHAFT POSITION (CMP) REMOVAL/INSTALLATION [MZI-3.5].)
SENSOR INSPECTION [MZI-3.5].) No Go to the next step.
• Is there any malfunction?
10 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to the next step.
CONNECTION No Go to the next step.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are any malfunction?
11 VERIFY TROUBLESHOOTING OF DTC P1336 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
12 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–203
1890-1U-06H(01-02).fm 204 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1397 [MZI-3.5]
id0102d1874000

DTC P1397
System voltage out of self-test range
• This DTC indicates that the 12-volt system voltage is too high or too low during the KOEO or KOER self-
DETECTION
test. It sets if the system voltage falls below or exceeds the calibrated threshold at any time during the
CONDITION
KOEO or KOER self-test.
POSSIBLE
• Battery or charging system concern.
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT THE BATTERY Yes Inspect charging system.
• Turn the ignition switch off. (See 01-03-5 QUICK DIAGNOSTIC CHART [MZI-3.5].)
• Inspect the battery. • If there is any malfunction, repair or replace
• Is the battery normal? malfunctioning part, then go to the next step.
No Replace the battery, then go to the next step.
4 VERIFY TROUBLESHOOTING OF DTC P1397 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO or KOER self-test using the
M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P1450 [MZI-3.5]
WM: DTC P14XX

id0102d1881900

DTC P1450 Unable to bleed up fuel tank vacuum

DETECTION • P1450 indicates the Self-Test has detected that the EVAP system is unable to bleed up fuel tank
CONDITION vacuum.
• Blockages or kinks in the charcoal canister tube or purge solenoid valve outlet tube (between fuel tank,
CV solenoid valve and charcoal canister).
• Fuel filler cap is stuck closed (no vacuum relief).
• Contaminated fuel vapor elbow on charcoal canister.
• Restricted charcoal canister.
POSSIBLE
• CV solenoid valve stuck open (partially or fully).
CAUSE
• Plugged CV solenoid valve filter.
• CV solenoid valve is stuck open.
• Power supply open (wiring harness near Fuel tank pressure sensor, Fuel tank pressure sensor or
PCM).
• Fuel tank pressure sensor malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS Yes Go to the next step.
BEEN RECORDED No Record FREEZE FRAME DATA on the repair order, then
• Has FREEZE FRAME DATA been go to the next step.
recorded?

01-02–204
1890-1U-06H(01-02).fm 205 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
2 VERIFY RELATED REPAIR Yes Perform repair or diagnosis according to the available
INFORMATION AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or • If the vehicle is not repaired, go to the next step.
on-line repair information availability. No Go to the next step.
• Is any related Service Bulletins
available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting. 01-02
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the No Go to the next step.
ON position (Engine off).
• Verify related pending code or stored
DTCs.
• Are other DTCs present?
4 INSPECT FOR VISUAL CAUSES OF Yes Remove any contamination or foreign material around fuel
EXCESSIVE FUEL TANK VACUUM vapor hoses and tubes.
• Verify kinks or bends in the fuel vapor Repair the hoses, tubes or components if necessary.
hoses and tubes. Go to Step 9.
• Visually inspect the charcoal canister No Go to the next step.
inlet port, CV solenoid valve, EVAP dust
separator or the outlet hose for
contamination or foreign material.
• Is a concern evident?
5 PERFORM EVAP LEAK TEST Yes Go to the next step.
• Connect the EVAP Leak Tester to the No Check to see if the CV solenoid valve is stuck open.
fuel filler pipe. Replace if necessary.
• Close the purge solenoid valve using (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT
the EVMV PID. (CV) SOLENOID VALVE, AIR FILTER COMPONENT
• Pressurize the EVAP system to 3.48 REMOVAL/INSTALLATION [MZI-3.5].)
kPa (PID FTP_H2O displays “14”). Go to Step 9.
• Does the pressure reach 3.48 kPa (PID
FTP_H2O displays “14”)?
6 INSPECT WHETHER CV SOLENOID Yes Go to the next step.
VALVE IS STUCK CLOSED No Check to see if the CV solenoid valve is stuck closed.
• Open the purge solenoid valve using the Replace if necessary.
EVMV PID. (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT
• Does the pressure drop immediately? (CV) SOLENOID VALVE, AIR FILTER COMPONENT
REMOVAL/INSTALLATION [MZI-3.5].)
Go to Step 9.
7 INSPECT FOR FUEL TANK PRESSURE Yes Go to the next step.
SENSOR PID WITHOUT PRESSURE No Replace the evaporative hose component.
APPLIED (See 01-40-30 FUEL TANK PRESSURE SENSOR
• Disconnect the charcoal canister outlet INSPECTION [MZI-3.5].)
tube at the charcoal canister. Go to the next step.
• Perform the KOEO self-test.
• Using M-MDS tester, select Diagnostic
Data Link.
• Select PCM.
• Select Active Command Modes.
• Access FTP V PID and record the
reading.
• Is the reading between 2.40 to 2.80 V?
8 EVAP SYSTEM LEAK TEST Yes Go to the next step.
• Connect all disconnected connectors No Leakage still exists.
and hoses. Locate leak point and repair.
• Perform the EVAP system leak test. Repeat this step.
(See 01-03-60 ENGINE CONTROL
SYSTEM OPERATION INSPECTION
[MZI-3.5].)
• Are the test results normal?

01-02–205
1890-1U-06H(01-02).fm 206 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 VERIFY TROUBLESHOOTING OF DTC Yes Replace the PCM, then go to the next step.
P1450 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
are reconnected.
• Turn the ignition switch to the ON
position (Engine off).
• Clear the DTC from the PCM memory
using the M-MDS.
• Start the engine and the perform “EVAP
system monitor drive cycle”
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC
present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR (See 01-02-12 DTC TABLE [MZI-3.5].)
PROCEDURE”. No Troubleshooting completed.
• (See 01-02-8 AFTER REPAIR
PROCEDURE [MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P145E [MZI-3.5]
id0102d1874100

DTC P145E PCV heater control circuit

DETECTION
• This DTC sets when the PCM detects a PCV valve heater circuit malfunction.
CONDITION
• Open circuit between PCV valve heater control terminal A and main relay No.1
• Open circuit between PCV valve heater fitting terminal A and main relay No.1
• Short to ground circuit between PCV valve heater control terminal B and PCM terminal 2BL
• Short to ground circuit between PCV valve heater fitting terminal B and PCM terminal 2AU
POSSIBLE
• Open circuit between PCV valve heater control terminal B and PCM terminal 2BL
CAUSE
• Open circuit between PCV valve heater fitting B and PCM terminal 2AU
• Connector or terminal malfunction
• PCV valve heater control malfunction
• PCV valve heater fitting malfunction

01-02–206
1890-1U-06H(01-02).fm 207 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P145E PCV heater control circuit
MAIN RELAY NO.1
PCV VALVE HEATER CONTROL PCM

8
3 4
A

01-02
3 5 7 6
B 2BL PCV VALVE HEATER CONTROL

PCV VALVE HEATER FITTING

8
3 4
A

3 5 7 6
B 2AU PCV VALVE HEATER FITTING

PCV VALVE HEATER CONTROL PCM

WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

PCV VALVE HEATER FITTING

WIRING HARNESS-SIDE CONNECTOR

B A

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.

01-02–207
1890-1U-06H(01-02).fm 208 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT PCV VALVE HEATER CONTROL AND Yes Repair or replace suspected part, then go to Step 9.
PCV VALVE HEATER FITTING CONNECTOR No Go to the next step.
FOR POOR CONNECTION
• Turn the ignition switch off.
• Disconnect PCV valve heater control and PCV
valve heater fitting connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT POWER SUPPLY CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 9.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect the voltage between the following
circuit:
— PCV valve heater control terminal A (wiring
harness-side) and body ground
— PCV valve heater fitting terminal A (wiring
harness-side) and body ground
• Are there voltage B+?
5 INSPECT PCV VALVE HEATER CONTROL AND Yes Repair or replace suspected part, then go to Step 9.
PCV VALVE HEATER FITTING CIRCUIT FOR No Go to the next step.
SHORT TO GROUND
• Turn the ignition switch off.
• Inspect for continuity between the following
circuit:
— PCV valve heater control terminal B (wiring
harness-side) and body ground
— PCV valve heater fitting terminal B (wiring
harness-side) and body ground
• Are there continuity?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step
• Turn the ignition switch off.
• Disconnect PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
7 INSPECT PCV VALVE HEATER CONTROL AND Yes Go to the next step.
PCV VALVE HEATER FITTING FOR OPEN No Repair or replace suspected part, then go to Step 9.
CIRCUIT
• Inspect for continuity between the following
circuit:
— PCV valve heater control terminal B (wiring
harness-side) and PCM terminal 2BL (wiring
harness-side)
— PCV valve heater fitting B (wiring harness-
side) and PCM terminal 2AU (wiring
harness-side)
• Are there continuity?
8 INSPECT PCV VALVE HEATER CONTROL AND Yes Replace the malfunctioning part, then go to the next step.
PCV VALVE HEATER FITTING No Go to the next step.
• Inspect the PCV valve heater control and PCV
valve heater fitting.
(See 01-16-10 POSITIVE CRANKCASE
VENTILATION (PCV) VALVE INSPECTION
[MZI-3.5].)
(See 01-16-13 POSITIVE CRANKCASE
VENTILATION (PCV) VALVE HEATER
FITTING INSPECTION [MZI-3.5].)
• Is there any malfunction?

01-02–208
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 VERIFY TROUBLESHOOTING OF DTC P145E Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using 01-02
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P1464 [MZI-3.5]
id0102d1874200

DTC P1464 A/C demand out of self-test range

DETECTION
• The DTC sets when the PCM receives a request for A/C during the self-test.
CONDITION
• A/C or defrost on during self-test
POSSIBLE • A/C relay circuit short to voltage
CAUSE • A/C switch malfunction
• A/C relay malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY A/C AND DEFROST ARE OFF DURING Yes Go to the next step.
SELF-TEST No Turn the A/C and defrost off. Then go to Step 5.
• Perform the “KOEO/KOER self-test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Are the A/C and defrost off during the self-test?
4 INSPECT ACCS PID Yes The ACCS PID indicates that the PCM is being requested
• Turn the ignition switch to the ON position to turn on the A/C. Inspect the A/C system.
(Engine off). (See 07-02-3 DIAGNOSTIC TROUBLE CODE NUMBER
• A/C and defroster OFF. INSPECTION.)
• Access the PCM and monitor the ACCS PID. Then go to the next step.
• Is the PID state ON? No The ACCS PID indicates that the ACCS input to the PCM is
low. Go to the next step.
5 VERIFY TROUBLESHOOTING OF DTC P1464 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO or KOER self-test using the
M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?

01-02–209
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P1500 [MZI-3.5]
WM: DTC P15XX

id0102d1874300

DTC P1500 Vehicle speed signal

DETECTION • Indicates the VSS input signal was intermittent. This DTC is set when a VSS concern interferes with other
CONDITION OBD tests, such as the catalyst efficiency monitor, the EVAP monitor, or the HO2S monitor.
• Intermittent sensor connections
POSSIBLE • Intermittent open in the sensor wiring harness circuit(s)
CAUSE • Intermittent short in the sensor wiring harness circuit(s)
• Sensor malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY STORED DTC IN DSC/RSC HU/CM Yes Go to the appropriate DTC inspection.
• Turn the ignition switch to the ON position (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
(Engine off). No Go to the next step.
• Verify stored DTCs in DSC/RSC HU/CM.
• Are DTCs stored?
4 VERIFY TROUBLESHOOTING OF DTC P1500 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–210
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1501 [MZI-3.5]
id0102d1825900

DTC P1501 Vehicle speed sensor (VSS) out of self-test range

DETECTION • Indicates that the vehicle speed input signal is out of the self-test range. If the PCM detects a vehicle speed
CONDITION input signal any time during the self-test, DTC P1501 is set and the test aborts.
POSSIBLE • Noise on the vehicle speed input signal from radio frequency interference/electro magnetic interference
CAUSE • External sources, such as ignition wires, the charging circuit, or aftermarket equipment
01-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY STORED DTC IN DSC/RSC HU/CM Yes Go to the appropriate DTC inspection.
• Turn the ignition switch to the ON position (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
(Engine off). No Go to the next step.
• Verify stored DTCs in DSC/RSC HU/CM.
• Are DTCs stored?
4 VERIFY TROUBLESHOOTING OF DTC P1501 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P16XX

01-02–211
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1633 [MZI-3.5]
id0102d1826400

DTC P1633 Keep alive power voltage too low

DETECTION
• Indicates the keep alive power circuit has experienced a voltage interrupt.
CONDITION
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit between battery positive terminal and PCM terminal 1BB
PCM

4 3
1BB

- +

BATTERY

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT BATTERY TERMINAL AND PCM Yes Repair or replace suspected part, then go to Step 5.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect battery terminal and PCM
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?

01-02–212
1890-1U-06H(01-02).fm 213 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT KEEP ALIVE POWER CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to the next step.
• Turn the ignition switch off.
• Disconnect battery cables.
• Disconnect PCM connector.
• Check continuity between battery positive
terminal (harness-side) and PCM terminal 1BB 01-02
(wiring harness-side).
• Is there continuity?
5 VERIFY TROUBLESHOOTING OF DTC P1633 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P1635 [MZI-3.5]
id0102d1826500

DTC P1635 Tire/axle out of acceptable range

DETECTION • This DTC indicates the tire and axle information contained in the vehicle identification block does not match
CONDITION the vehicle hardware.
• Incorrect tire size
POSSIBLE
• Incorrect axle ratio
CAUSE
• Incorrect vehicle identification configuration parameters

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins and/or on-line • If vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY VEHICLE IDENTIFICATION TIRE DATA Yes Go to the next step.
• Turn the ignition switch to the ON position. No Perform PCM configuration procedure, then go to Step 5.
• Connect the M-MDS to the DLC-2. (See 01-40-7 PCM CONFIGURATION [MZI-3.5].)
• Access the data of the tire size.
• Is it the same as a equipped tire?
4 VERIFY GENUINE TIRES ARE INSTALLED Yes Go to the next step.
• Is genuine tires are equipped? No Change to the genuine tire. then go to the next step.
5 VERIFY TROUBLESHOOTING OF DTC P1635 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear DTC from PCM memory using M-MDS.
• Start engine and warm up it completely.
• Is same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PRECAUTION”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

01-02–213
1890-1U-06H(01-02).fm 214 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

End Of Sie

DTC P1639 [MZI-3.5]

id0102d1826600

DTC P1639 Vehicle ID block corrupted, that not programmed

DETECTION
• This DTC indicates that the VID block is not programmed or the information within is corrupt.
CONDITION
• New PCM
POSSIBLE
• Incorrect PCM
CAUSE
• Incorrect VID configuration

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Perform the PCM reprogramming procedure.
• Is any related Service Bulletins available? (See 01-40-7 PCM CONFIGURATION [MZI-3.5].)
Then go to the next step.
3 VERIFY TROUBLESHOOTING OF DTC P1639 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and perform the KOEO and
KOER self-test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P1650 [MZI-3.5]
id0102d1826700

DTC P1650 PSP switch out of self-test range

DETECTION • In the KOEO self-test, this DTC indicates the PSP input to the PCM is high. In the KOER self-test, this DTC
CONDITION indicates the PSP input did not change state.
• The steering wheel must be turned during KOER self-test
POSSIBLE • PSP switch malfunction
CAUSE • Open circuit between PSP switch terminal A and PCM terminal 2I
• Short to ground circuit between PSP switch terminal A and PCM terminal 2I

01-02–214
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P1650 PSP switch out of self-test range
PCM

PSP SWITCH

3 4 6 5
A 2I
01-02

PCM
WIRING HARNESS-SIDE CONNECTOR
PSP SWITCH
WIRING HARNESS-SIDE CONNECTOR
2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C
A

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins and/or on-line • If vehicle is not repaired, go to next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT PSP SWITCH CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 8.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT PSP SWITCH CIRCUIT FOR SHORT Yes Repair or replace suspected part, then go to Step 8.
TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between PSP switch
terminal A (wiring harness-side) and body
ground.
• Is there continuity?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?

01-02–215
1890-1U-06H(01-02).fm 216 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
6 INSPECT PSP SWITCH CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Inspect for continuity between PSP switch
terminal A (wiring harness-side) and PCM
terminal 2I (wiring harness-side)
• Is there continuity?
7 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
8 VERIFY TROUBLESHOOTING OF DTC P1650 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Start the engine.
• Clear DTC from PCM memory using M-MDS.
• Perform the “KOEO/KOER Self-Test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P1674 [MZI-3.5]
id0102d1882100

DTC P1674 Control module software corrupted

DETECTION
• Indicates that an error occurred in the PCM. This DTC is set in combination with P2105.
CONDITION
POSSIBLE • Software incompatibility issue
CAUSE • PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Perform the PCM reprogramming procedure.
• Is any related Service Bulletins available? (See 01-40-7 PCM CONFIGURATION [MZI-3.5].)Then go
to the next step.
3 VERIFY TROUBLESHOOTING OF DTC P1674 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors are No Go to the next step.
reconnected.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and perform the KOEO and
KOER self-test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?

01-02–216
1890-1U-06H(01-02).fm 217 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See (01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie 01-02

DTC P1703 [MZI-3.5]
WM: DTC P17XX

id0102d1826900

DTC P1703 Brake switch out of self-test range

DETECTION • Indicates that during the KOEO self-test, the brake pedal position signal was high, or during the KOER self-
CONDITION test, the BPP signal did not cycle high and low.
• Connector or terminal malfunction
POSSIBLE • Brake switch No.1 malfunction
CAUSE • Brake switch No.1 mis installation
• Brake switch No.1 circuit malfunction

4
BRAKE SWITCH NO.1/
BATTERY BRAKE SWITCH NO.2
PCM

6 NO. 1 6
B D 1T BRAKE SWITCH NO.1

7 7
MAIN RELAY
A C
NO.1 8
NO. 2
1P BRAKE SWITCH NO.2

PCM
BRAKE SWITCH NO.1/ WIRING HARNESS-SIDE CONNECTOR
MAIN RELAY NO.1
BRAKE SWITCH NO.2
A E
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
C C A 1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

D D B
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service
AVAILABILITY Bulletins.
• Verify related Service Bulletins availability. • If vehicle is not repaired, go to next step.
• Is any related Service Bulletins available? No Go to next step.

01-02–217
1890-1U-06H(01-02).fm 218 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 VERIFY THE BRAKE PEDAL WAS APPLIED Yes Go to next step.
• Was the brake pedal applied and released No Perform the KOER self-test.
during the KOEO self-test? Apply and release the brake pedal during the KORE test,
then go to Step 10
(See 01-02-8 KOEO/KOER SELF TEST [MZI-3.5].)
4 INSPECT THE OPERATION OF THE BLAKE/ Yes Go to next step.
TAILLIGHT No Repair or replace harness or blake/taillight, then go to Step
• Turn the ignition switch to the ON position 10.
(Engine off).
• Depress and release the brake pedal and
check the blake/taillight operation.
• Do the blake/taillight operate correctly?
5 INSPECT THE CRUISE CONTROL OPERATION Yes Go to next step.
• Check for cruise control operation. No Repair or replace suspected part, then go to Step 10.
• Does the cruise control operate correctly?
6 INSPECT BRAKE SWITCH AND PCM Yes Repair or replace suspected part, then go to Step 10.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the throttle body connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
7 INSPECT BRAKE SWITCH NO.1 CIRCUIT Yes Go to next step.
MALFUNCTION No Repair or replace suspected part, then go to Step 10.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between PCM terminal 1T
(wiring harness-side) and body ground.
• Verify the following values when the brake
pedal to the floor and releasing.
— Brake pedal fully depressed: more than 10 V
— Brake pedal fully released: less than 1.0 V
• Is the voltage normal?
8 INSPECT BRAKE SWITCH Yes Repair or replace suspected part, then go to Step 10.
• Inspect the brake switch. No Go to the next step.
(See 04-11-7 BRAKE SWITCH INSPECTION.)
• Is there any malfunction?
9 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
10 VERIFY TROUBLESHOOTING OF DTC P1703 Yes Replace the PCM, then go to next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to next step.
reconnected.
• Clear DTC from memory using M-MDS.
• Perform KOEO/KOER Self-Test.
• Is PENDING CODE same as DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
SOKYU_WM: DTC P21XX

01-02–218
1890-1U-06H(01-02).fm 219 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2100 [MZI-3.5]
id0102d1811000

DTC P2100 Throttle actuator circuit open

DETECTION
• A PCM malfunction flag is set indicating the motor circuit is open.
CONDITION
• Throttle actuator malfunction
• Connector or terminal malfunction
• Open circuit wiring harness between throttle body terminal A and PCM terminal 2BO 01-02
POSSIBLE
• Short to power supply in wiring harness between throttle body terminal A and PCM terminal 2BO
CAUSE
• Open circuit wiring harness between throttle body terminal B and PCM terminal 2BR
• Short to power supply in wiring harness between throttle body terminal B and PCM terminal 2BR
• Throttle actuator circuits are shorted each other
THROTTLE ACTUATOR
(THROTTLE BODY) PCM

3 5 7 8 6
B 2BR THROTTLE ACTUATOR (+)

4
3 5 7 8 6
A 2BO THROTTLE ACTUATOR (-)

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT THROTTLE BODY CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 9.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Disconnect the throttle body connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–219
1890-1U-06H(01-02).fm 220 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT THE THROTTLE ACTUATOR Yes Replace the throttle body, then go to Step 9.
• Inspect the throttle actuator. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
(See 01-13-7 THROTTLE BODY INSPECTION INSTALLATION [MZI-3.5].)
[MZI-3.5].) No Go to the next step.
• Is there malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 9.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
6 INSPECT THROTTLE ACTUATOR CONTROL Yes Go to the next step.
CIRCUIT FOR OPEN No Repair or replace suspected part, then go to Step 9.
• Disconnect the PCM connector.
• Inspect for continuity between the following
terminals:
— Throttle body terminal A and PCM terminal
2BO
— Throttle body terminal B and PCM terminal
2BR
• Are there continuity?
7 INSPECT TP SENSOR SIGNAL CIRCUITS FOR Yes Go to the next step.
SHORT EACH OTHER No Repair or replace suspected part, then go to Step 9.
• Turn the ignition switch off.
• Disconnect the throttle body and PCM
connector.
• Measure resistance between throttle body
terminal A and B.
• Is the resistance more than 10 kilohms?
8 INSPECT HROTTLE ACTUATOR CONTROL Yes Repair or replace suspected part, then go to the next step.
CIRCUIT FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals:
— Throttle body terminal A and body ground.
— Throttle body terminal B and body ground.
• Are there voltage B+?
9 VERIFY TROUBLESHOOTING OF DTC P2100 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO or KOER self-test using the
M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–220
1890-1U-06H(01-02).fm 221 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2101 [MZI-3.5]
id0102d1811100

DTC P2101 Throttle actuator circuit range/performance

DETECTION
• A PCM malfunction flag is set indicating the motor circuit is open, and may require cycling the key.
CONDITION
POSSIBLE
• Throttel actuator circuit are cross-wired
CAUSE
01-02
THROTTLE ACTUATOR
(THROTTLE BODY) PCM

4 4
B 2BR THROTTLE ACTUATOR (+)

4 4
A 2BO THROTTLE ACTUATOR (-)

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs FOR ALL OF VEHICLE MODULE (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 INSPECT THROTTLE BODY AND PCM Yes Repair or replace suspected part, then go to Step 6.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the throttle body and PCM
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?

01-02–221
1890-1U-06H(01-02).fm 222 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
6 VERIFY TROUBLESHOOTING OF DTC P2101 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Start the engine.
• Clear DTC from PCM memory using M-MDS.
• Perform the “KOEO/KOER Self-Test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P2104, P2105, P2110 [MZI-3.5]
id0102d1882300

DTC P2104 P2104: Throttle actuator control system - forced idle

DTC P2105 P2105: Throttle actuator control system - forced engine shutdown
DTC P2110 P2110: Throttle actuator control system - forced limited RPM
DETECTION • The TAC system is in the failure mode effects management (FMEM) mode.
CONDITION
POSSIBLE • This DTC is an informational DTC and may be set in combination with a number of other DTCs which are
CAUSE causing the FMEM.Diagnose other DTCs first.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair
• Has FREEZE FRAME DATA been recorded? order, then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the
AVAILABILITY available Service Bulletins.
• Verify related Service Bulletins and/or on-line repair • If the vehicle is not repaired, go to the next
information availability. step.
• Is any related Service Bulletins available? No Perform the PCM reprogramming procedure.
(See 01-40-7 PCM CONFIGURATION [MZI-3.5].)
Then go to the next step.
3 VERIFY RELATED PENDING CODE OR STORED Yes Go to the appropriate DTC troubleshooting.
DTCs FOR ALL OF VEHICLE MODULE (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON position No Go to the next step.
(Engine off).
• Verify related pending code or stored DTCs.
• Is other DTCs present?
4 PERFORM VISUAL INSPECTION Yes Isolate the concern and repair if necessary.
• Turn the ignition switch off. Then go to Step 6.
• Visually inspect the following for obvious signs of No Go to the next step.
damage:
— Throttle body
— PCM
• Is a concern present?

01-02–222
1890-1U-06H(01-02).fm 223 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
5 INSPECT ACCELERATOR PEDAL POSITION (APP) Yes Repair or replace if necessary.
SENSOR Then go to the next step.
• Perform the APP sensor inspection No Go to the next step.
(See 01-40-14 ACCELERATOR PEDAL POSITION
(APP) SENSOR INSPECTION [MZI-3.5].)
• Is a concern present?
6 VERIFY TROUBLESHOOTING OF MISFIRE DTC Yes Replace the PCM, then go to the next step. 01-02
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION
• Verify that all disconnected connectors are [MZI-3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position (Engine
off).
• Clear the DTC from the PCM memory using the M-
MDS.
• Perform the KOEO and KOER self test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE [MZI- No Troubleshooting completed.
3.5].)
• Are any DTC present?

End Of Sie
DTC P2107 [MZI-3.5]
id0102d1811400

DTC P2107 Throttle actuator control module processor

DETECTION
• The throttle actuator control area of the PCM failed the self-test.
CONDITION
• Throttle body malfunction
• Throttle actuator control circuits are shorted each other
POSSIBLE
• Short to power supply between throttle actuator terminal A and PCM terminal 2BO
CAUSE
• Short to power supply between throttle actuator terminal B and PCM terminal 2BR
• PCM malfunction
THROTTLE ACTUATOR
(THROTTLE BODY) PCM

3 4 5
B 2BR THROTTLE ACTUATOR (+)

6
3 4 5
A 2BO THROTTLE ACTUATOR (-)

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–223
1890-1U-06H(01-02).fm 224 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT MAF SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 8.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT THROTTLE ACTUATOR CONTROL Yes Repair or replace suspected part, then go to Step 8.
CIRCUIT FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure voltage between the following circuits:
— Throttle actuator terminal A (wiring harness-
side) and body ground.
— Throttle actuator terminal B (wiring harness-
side) and body ground.
• Are there voltage B+?
5 INSPECT THROTTLE ACTUATOR CONTROL Yes Go to the next step.
CIRCUITS FOR SHORT EACH OTHER No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch off.
• Disconnect the throttle body and PCM
connector.
• Measure resistance between throttle actuator
terminal A and B.
• Is the resistance more than 10 kilohms?
6 INSPECT THROTTLE ACTUATOR Yes Replace the throttle body, then go to Step 8.
• Inspect the throttle actuator. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
(See 01-13-7 THROTTLE BODY INSPECTION INSTALLATION [MZI-3.5].)
[MZI-3.5].) No Go to the next step.
• Is there any malfunction?
7 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
8 VERIFY TROUBLESHOOTING OF DTC P2107 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Start the engine.
• Clear DTC from PCM memory using M-MDS.
• Perform the “KOEO/KOER Self-Test”.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–224
1890-1U-06H(01-02).fm 225 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2111 [MZI-3.5]
id0102d1874700

DTC P2111 Throttle actuator control system - stuck open

DETECTION
• This PCM fault status indicates the throttle plate is at a more angle than commanded.
CONDITION
• Binding throttle body, stuck open
POSSIBLE • Throttle actuator control circuits are cross-wired
CAUSE • Throttle actuator control circuits are shorted each other 01-02
• PCM malfunction
THROTTLE BODY PCM

D 2D

8
B 2BR THROTTLE ACTUATOR (+)

8
A 2BO THROTTLE ACTUATOR (-)

4 7
F 2Z TP SENSOR NO.1

C 2AD TP SENSOR NO.2

E 2AH

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–225
1890-1U-06H(01-02).fm 226 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT THROTTLE POSITION OPEN CIRCUIT Yes Go to the Step 5.
AND CLOSED VOLTAGES No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Access the PCM and monitor the TP1 and TP2
PIDs.
• Verify the following values of the PIDs when
depressing the accelerator pedal to the floor
and releasing.
— Pedal fully released: TP1 is 3.7—4.7 V
— Pedal fully released: TP2 is 0.3—1.9 V
— Pedal fully depressed: TP1 is 0.7—2.9 V
— Pedal fully depressed: TP2 is 4.1—4.7 V
• Are both PIDs within the specification?
4 INSPECT FOR OBSTRUCTION OF THROTTLE Yes Go to the Step 7.
BODY No Isolate and repair the obstruction. Then go to Step 9.

Warning
• Substantial opening and closing torque
is applied by this system. To prevent
injury, be careful to keep fingers away
from throttle mechanism when actuated.
Failure to follow these instructions may
result in personal injury.

• Turn the ignition switch off.

• Remove the air hose from the throttle body.
• Visually inspect for throttle plate obstructions or
sludge.
• Slowly, push the throttle plate to wide open and
release.
• Does the throttle plate move freely to wide
open and back?
5 INSPECT TP SENSOR OPERATION Yes Go to the next step.
• Turn the ignition switch to the ON position No Replace the throttle body. Then go to Step 9.
(Engine off).
• Access the PCM and monitor the TP1 and TP2
PIDs.
• Slowly press the accelerator pedal from fully
released to fully depressed while observing the
voltage readings.
• Use the chart as a reference.
• Inspect the TP sensor.
(See 01-40-12 THROTTLE POSITION (TP)
SENSOR INSPECTION [MZI-3.5].)
• Do all signal values smoothly change when the
accelerator is depressed?
6 INSPECT TP SENSOR CIRCUIT FOR Yes Go to the next step.
INTERMITTENT CONCERN No Repair or replace suspected part, then go to Step 9.
• Access the PCM and monitor the TP1 and TP2
PIDs.
• Wiggle, shake, and bend the wiring harness
from the TP to the PCM.
• Are the voltages between 0.49—4.65 V?
7 INSPECT THROTTLE ACTUATOR CONTROL Yes Replace the throttle body. Then go to Step 9.
MOTOR VISUALLY No Go to the next step.

Note
• Make sure the throttle body connector is
properly connected.

• Turn the ignition switch off.

• Inspect the throttle actuator control motor for
damaged housing, wiring harness connector,
and wiring harness.
• Are there any concerns with the throttle
actuator control motor hardware?

01-02–226
1890-1U-06H(01-02).fm 227 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
8 INSPECT THROTTLE ACTUATOR CONTROL Yes Go to the next step.
CIRCUITS FOR SHORT EACH OTHER No Repair or replace suspected part, then go to the next step.
• Turn the ignition switch off.
• Disconnect the throttle body and PCM
connector.
• Measure resistance between throttle actuator
terminal A and B. 01-02
• Is the resistance more than 10 kilohms?
9 VERIFY TROUBLESHOOTING OF DTC P2111 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P21XX

01-02–227
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2112 [MZI-3.5]
id0102d1840300

DTC P2112 Throttle actuator control system - stuck closed

DETECTION
• This PCM fault status indicates the throttle plate is at a lower angle than commanded.
CONDITION
• Binding throttle body, stuck open
POSSIBLE • Throttle actuator control circuits are cross-wired
CAUSE • Throttle actuator control circuits are shorted each other
• PCM malfunction
THROTTLE BODY PCM

D 2D

8
B 2BR THROTTLE ACTUATOR (+)

8
A 2BO THROTTLE ACTUATOR (-)
4 7
F 2Z TP SENSOR NO.1

C 2AD TP SENSOR NO.2

E 2AH

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–228
1890-1U-06H(01-02).fm 229 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT THROTTLE POSITION OPEN CIRCUIT Yes Go to the Step 5.
AND CLOSED VOLTAGES No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Access the PCM and monitor the TP1 and TP2
PIDs.
• Verify the following values of the PIDs when 01-02
depressing the accelerator pedal to the floor
and releasing.
— Pedal fully released: TP1 is 3.7—4.7 V
— Pedal fully released: TP2 is 0.3—1.9 V
— Pedal fully depressed: TP1 is 0.7—2.9 V
— Pedal fully depressed: TP2 is 4.1—4.7 V
• Are both PIDs within the specification?
4 INSPECT FOR OBSTRUCTION OF THROTTLE Yes Go to the Step 7.
BODY No Isolate and repair the obstruction. Then go to Step 9.

Warning
• Substantial opening and closing torque
is applied by this system. To prevent
injury, be careful to keep fingers away
from throttle mechanism when actuated.
Failure to follow these instructions may
result in personal injury.

• Turn the ignition switch off.

• Remove the air hose from the throttle body.
• Visually inspect for throttle plate obstructions or
sludge.
• Slowly, push the throttle plate to wide open and
release.
• Does the throttle plate move freely to wide
open and back?
5 INSPECT TP SENSOR OPERATION Yes Go to the next step.
• Turn the ignition switch to the ON position No Replace the throttle body. Then go to Step 9.
(Engine off).
• Access the PCM and monitor the TP1 and TP2
PIDs.
• Slowly press the accelerator pedal from fully
released to fully depressed while observing the
voltage readings.
• Use the chart as a reference.
• Inspect the TP sensor.
(See 01-40-12 THROTTLE POSITION (TP)
SENSOR INSPECTION [MZI-3.5].)
• Do all signal values smoothly change when the
accelerator is depressed?
6 INSPECT TP SENSOR CIRCUIT FOR Yes Go to the next step.
INTERMITTENT CONCERN No Repair or replace suspected part, then go to Step 9.
• Access the PCM and monitor the TP1 and TP2
PIDs.
• Wiggle, shake, and bend the wiring harness
from the TP to the PCM.
• Are the voltages between 0.49—4.65 V?
7 INSPECT THROTTLE ACTUATOR CONTROL Yes Replace the throttle body. Then go to Step 9.
MOTOR VISUALLY No Go to the next step.

Note
• Make sure the throttle body connector is
properly connected.

• Turn the ignition switch off.

• Inspect the throttle actuator control motor for
damaged housing, wiring harness connector,
and wiring harness.
• Are there any concerns with the throttle
actuator control motor hardware?

01-02–229
1890-1U-06H(01-02).fm 230 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
8 INSPECT THROTTLE ACTUATOR CONTROL Yes Go to the next step.
CIRCUITS FOR SHORT EACH OTHER No Repair or replace suspected part, then go to the next step.
• Turn the ignition switch off.
• Measure resistance between throttle actuator
terminal A and B.
• Is the resistance more than 10 kilohms?
9 VERIFY TROUBLESHOOTING OF DTC P2112 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the “KOEO or KOER self-test” using
the M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
DTC P2121, P2126, P2131 [MZI-3.5]
SOKYU_WM: DTC P21XX

id0102d1875500

DTC P2121 APP sensor No.1 circuit range/performance

DTC P2126 APP sensor No.2 circuit range/performance
DTC P2131 APP sensor No.3 circuit range/performance
DETECTION • APP sensor fault flag is set for sensor No.1, No.2 and No.3 by the PCM, indicating the signal is out of the
CONDITION normal self-test operating range.
• APP sensor signal circuits are shorted each other
• APP sensor malfunction
• PCM malfunction
P2121
— Open circuit wiring harness between APP sensor terminal E and PCM terminal 1AK
— Short to ground circuit between APP sensor terminal E and PCM terminal 1AK
— Short to power supply in wiring harness between APP sensor terminal E and PCM terminal 1AK
POSSIBLE
P2126
CAUSE
— Open circuit wiring harness between APP sensor terminal H and PCM terminal 1AG
— Short to ground circuit between APP sensor terminal H and PCM terminal 1AG
— Short to power supply in wiring harness between APP sensor terminal H and PCM terminal 1AG
P2131
— Open circuit wiring harness between APP sensor terminal B and PCM terminal 1AC
— Short to ground circuit between APP sensor terminal B and PCM terminal 1AC
— Short to power supply in wiring harness between APP sensor terminal B and PCM terminal 1AC

01-02–230
1890-1U-06H(01-02).fm 231 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2121 APP sensor No.1 circuit range/performance
DTC P2126 APP sensor No.2 circuit range/performance
DTC P2131 APP sensor No.3 circuit range/performance

APP SENSOR PCM

5
F 1BA
7
01-02
D 1Y

8 9 10 11
E 1AK APP SENSOR NO.1

8 9 10 11
H 1AG APP SENSOR NO.2

8 9 10 11
B 1AC APP SENSOR NO.3

5
G 1AD

5
C 1AH

PCM
WIRING HARNESS-SIDE CONNECTOR
APP SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

G E C A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
H F D B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT ACCELERATOR PEDAL FOR Yes Go to the next step.
OBSTRUCTION No Isolate and repair the obstruction.Then go to Step 12.
• Turn the ignition switch to the ON position
(Engine off).
• Depress the accelerator pedal fully to the floor
and release.
• Does the pedal move freely to the floor and
back?

01-02–231
1890-1U-06H(01-02).fm 232 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
4 INSPECT APP SENSOR SIGNAL VOLTAGE Yes Go to the next step.
RANGES FOR ACCELERATOR PEDAL FULLY No Go to Step 6.
APPLIED AND DEPRESS POSITIONS
• Access the PCM and monitor the APP1, APP2
and APP3 PIDs.
• Verify the following values of the PIDs when
depressing the accelerator pedal fully to the
floor.
— APP1: 0.48—1.79 V
— APP2: 2.95—4.62 V
— APP3: 2.43—4.02 V
• Verify the following values of the PIDs when
press the accelerator pedal release.
— APP1: 3.43—4.69 V
— APP2: 1.13—1.88 V
— APP3: 0.64—1.28 V
• Are all PIDs signals out of range for the pedal
fully depressing and released positions?
5 INSPECT REFERENCE VOLTAGE TO APP Yes Go to the next step.
SENSOR No Repair if necessary.Then go to Step 12.
• Turn the ignition switch off.
• Disconnect the APP sensor connector.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the APP sensor
connector D or F terminal (wiring harness side)
and the APP sensor connector C or G terminal
(wiring harness side)
• Is the voltage between 4—6 V?
6 INSPECT FUNCTIONALITY OF APP CIRCUITS Yes Go to the next Step.
No Go to Step 11.
Note
• Use the voltage measurements from Step 4.

• Are APP1, APP2 or APP3 out of range?

7 INSPECT FUNCTIONALITY OF APP SENSOR Yes Go to next Step.
• Turn the ignition switch off. No Replace the accelerator pedal. Then go to Step 12.
• Disconnect the APP sensor connector.
• Measure the resistance between the following
APP sensor terminals (APP sensor component
side).
— E and D or F: 600—1,370 ohms
— E and C or G: 720—1,660 ohms
— E and H: 1,300—2,960 ohms
— E and B: 1,250—2,860 ohms
— H and D or F: 750—1,720 ohms
— H and C or G: 660—1,520 ohms
— H and B: 1,230—2,810 ohms
— B and D or F: 710—1,640 ohms
— B and C or G: 580—1,340 ohms
— D or F and C or G: 200—470 ohms
• Are all the resistances within specifications?
8 INSPECT APP SENSOR SIGNAL CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 12.
• Disconnect the PCM connector.
• Inspect for continuity between the following
terminals:
— P2121:
APP sensor terminal E and PCM terminal
1AK
— P2126:
APP sensor terminal H and PCM terminal
1AG
— P2131:
APP sensor terminal B and PCM terminal
1AC
• Are there continuity?

01-02–232
1890-1U-06H(01-02).fm 233 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
9 INSPECT APP SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 12.
SHORT TO GROUND No Go to the next Step.
• Turn the ignition switch off.
• Inspect for continuity between the following
terminals:
— P2121:
APP sensor terminal E and body ground 01-02
— P2126:
APP sensor terminal H and body ground
— P2131:
APP sensor terminal B and body ground
• Are there continuity?
10 INSPECT APP SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 12.
SHORT TO POWER SUPPLY No Go to the next Step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals:
— P2121:
APP sensor terminal E and body ground
— P2126:
APP sensor terminal H and body ground
— P2131:
APP sensor terminal B and body ground
• Are the voltage B+?
11 INSPECT APP SENSOR SIGNAL CIRCUIT FOR Yes Go to the next step.
SHORT EACH OTHER No Repair or replace suspected part, then go to the next step.
• Turn the ignition switch off.
• Disconnect PCM connector.
• Disconnect APP sensor connector.
• Measure the resistance between the following
APP sensor terminals (wiring harness-side)
— P2121
E and H
E and B
E and D or F
E and C or G
— P2126
H and E
H and B
H and D or F
H and C or G
— P2131
B and E
B and H
B and D or F
B and C or G
• Are there resistance greater than 10 kilohms?
12 VERIFY TROUBLESHOOTING OF DTC P2121, Yes Replace the PCM, then go to the next step.
P2126 or P2131 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO or KOER self-test using the
M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
13 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–233
1890-1U-06H(01-02).fm 234 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2122 [MZI-3.5]
id0102d1811700

DTC P2122 APP sensor No.1 circuit low input

DETECTION
• APP sensor No.1 is out of self-test range low.
CONDITION
• Short to ground circuit between APP sensor terminal F and PCM terminal 1BA
• Short to ground circuit between APP sensor terminal D and PCM terminal 1Y
• Short to ground circuit between APP sensor terminal G and PCM terminal 1AD
POSSIBLE
• Short to ground circuit between APP sensor terminal C and PCM terminal 1AH
CAUSE
• Short to ground circuit between APP sensor terminal E and PCM terminal 1AK
• Connector or terminal malfunction
• APP sensor malfunction
APP SENSOR PCM
3 4 6
F 1BA
3 4 6
D 1Y
3 4 6
E 1AK APP SENSOR NO.1
3 6
5 H 1AG APP SENSOR NO.2
3 6
B 1AC APP SENSOR NO.3
3 4 6
G 1AD
3 4 6
C 1AH

PCM
WIRING HARNESS-SIDE CONNECTOR
APP SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

G E C A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
H F D B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

01-02–234
1890-1U-06H(01-02).fm 235 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 7.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the APP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT APP SENSOR NO.1 CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 7.
SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between the following
terminals:
— APP sensor terminal F and body ground.
— APP sensor terminal D and body ground.
— APP sensor terminal G and body ground.
— APP sensor terminal C and body ground.
— APP sensor terminal E and body ground.
• Are there continuity?
5 INSPECT APP SENSOR NO.1 Yes Replace the accelerator pedal, then go to Step 7.
• Inspect APP sensor No.1. (See 01-13-8 ACCELERATOR PEDAL REMOVAL/
(See 01-40-14 ACCELERATOR PEDAL INSTALLATION [MZI-3.5].)
POSITION (APP) SENSOR INSPECTION No Go to the next step.
[MZI-3.5].)
• Is there any malfunction?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
7 VERIFY TROUBLESHOOTING OF DTC P2122 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–235
1890-1U-06H(01-02).fm 236 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2123 [MZI-3.5]
id0102d1811800

DTC P2123 APP sensor No.1 circuit high input

DETECTION
• APP sensor No.1 is out of self-test range high.
CONDITION
• Open circuit wiring harness between APP sensor terminal F and PCM terminal 1BA
• Open circuit wiring harness between APP sensor terminal D and PCM terminal 1Y
• Open circuit wiring harness between APP sensor terminal G and PCM terminal 1AD
• Open circuit wiring harness between APP sensor terminal C and PCM terminal 1AH
• Open circuit wiring harness between APP sensor terminal E and PCM terminal 1AK
POSSIBLE • Short to power supply in wiring harness between APP sensor terminal F and PCM terminal 1BA
CAUSE • Short to power supply in wiring harness between APP sensor terminal D and PCM terminal 1Y
• Short to power supply in wiring harness between APP sensor terminal G and PCM terminal 1AD
• Short to power supply in wiring harness between APP sensor terminal C and PCM terminal 1AH
• Short to power supply in wiring harness between APP sensor terminal E and PCM terminal 1AK
• Connector or terminal malfunction
• APP sensor malfunction

APP SENSOR PCM

3 6 7 5
F 1BA
3 6 7 5
D 1Y
3 6 7 5
E 1AK APP SENSOR NO.1
3 5
4 H 1AG APP SENSOR NO.2
3 5
B 1AC APP SENSOR NO.3
3 6 7 5
G 1AD
3 6 7 5
C 1AH

PCM
WIRING HARNESS-SIDE CONNECTOR
APP SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

G E C A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
H F D B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–236
1890-1U-06H(01-02).fm 237 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 8.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the APP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction? 01-02
4 INSPECT APP SENSOR NO.1 Yes Replace the accelerator pedal, then go to Step 8.
• Inspect APP sensor No.1. (See 01-13-8 ACCELERATOR PEDAL REMOVAL/
(See 01-40-14 ACCELERATOR PEDAL INSTALLATION [MZI-3.5].)
POSITION (APP) SENSOR INSPECTION No Go to the next step.
[MZI-3.5].)
• Is there any malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
6 INSPECT APP SENSOR NO.1 CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch off.
• Inspect for continuity between the following
terminals (wiring harness-side).
— APP sensor terminal F and PCM terminal
1BA.
— APP sensor terminal D and PCM terminal
1Y.
— APP sensor terminal G and PCM terminal
1AD.
— APP sensor terminal C and PCM terminal
1AH.
— APP sensor terminal E and PCM terminal
1AK.
• Are there continuity?
7 INSPECT APP SENSOR NO.1 SIGNAL CIRCUIT Yes Repair or replace suspected part, then go to Step 8.
FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals (wiring harness-side).
— APP sensor terminal F and body ground.
— APP sensor terminal D and body ground.
— APP sensor terminal G and body ground.
— APP sensor terminal C and body ground.
— APP sensor terminal E and body ground.
• Are there voltage B+?
8 VERIFY TROUBLESHOOTING OF DTC P2123 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–237
1890-1U-06H(01-02).fm 238 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2127 [MZI-3.5]
id0102d1811900

DTC P2127 APP sensor No.2 circuit low input

DETECTION
• APP sensor No.2 is out of self-test range low.
CONDITION
• Short to ground circuit between APP sensor terminal F and PCM terminal 1BA
• Short to ground circuit between APP sensor terminal D and PCM terminal 1Y
• Short to ground circuit between APP sensor terminal G and PCM terminal 1AD
POSSIBLE
• Short to ground circuit between APP sensor terminal C and PCM terminal 1AH
CAUSE
• Short to ground circuit between APP sensor terminal H and PCM terminal 1AG
• Connector or terminal malfunction
• APP sensor malfunction

APP SENSOR PCM

3 4 6
F 1BA
3 4 6
D 1Y
3 6
E 1AK APP SENSOR NO.1
3 4 6
5 H 1AG APP SENSOR NO.2

3 6
APP SENSOR NO.3
B 1AC
3 4 6
G 1AD
3 4 6
C 1AH

PCM
WIRING HARNESS-SIDE CONNECTOR
APP SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

G E C A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
H F D B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

01-02–238
1890-1U-06H(01-02).fm 239 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 7.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the APP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT APP SENSOR NO.2 CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 7.
SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between the following
terminals:
— APP sensor terminal F and body ground.
— APP sensor terminal D and body ground.
— APP sensor terminal G and body ground.
— APP sensor terminal C and body ground.
— APP sensor terminal H and body ground.
• Are there continuity?
5 INSPECT APP SENSOR NO.2 Yes Replace the accelerator pedal, then go to Step 7.
• Inspect APP sensor No.2. (See 01-13-8 ACCELERATOR PEDAL REMOVAL/
(See 01-40-14 ACCELERATOR PEDAL INSTALLATION [MZI-3.5].)
POSITION (APP) SENSOR INSPECTION No Go to the next step.
[MZI-3.5].)
• Is there any malfunction?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
7 VERIFY TROUBLESHOOTING OF DTC P2127 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–239
1890-1U-06H(01-02).fm 240 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2128 [MZI-3.5]
id0102d1812000

DTC P2128 APP sensor No.2 circuit high input

DETECTION
• APP sensor No.2 is out of self-test range high.
CONDITION
• Open circuit wiring harness between APP sensor terminal F and PCM terminal 1BA
• Open circuit wiring harness between APP sensor terminal D and PCM terminal 1Y
• Open circuit wiring harness between APP sensor terminal G and PCM terminal 1AD
• Open circuit wiring harness between APP sensor terminal C and PCM terminal 1AH
• Open circuit wiring harness between APP sensor terminal H and PCM terminal 1AG
POSSIBLE • Short to power supply in wiring harness between APP sensor terminal F and PCM terminal 1BA
CAUSE • Short to power supply in wiring harness between APP sensor terminal D and PCM terminal 1Y
• Short to power supply in wiring harness between APP sensor terminal G and PCM terminal 1AD
• Short to power supply in wiring harness between APP sensor terminal C and PCM terminal 1AH
• Short to power supply in wiring harness between APP sensor terminal H and PCM terminal 1AG
• Connector or terminal malfunction
• APP sensor malfunction
APP SENSOR PCM
3 6 7 5
F 1BA
3 6 7 5
D 1Y

3 5
E 1AK APP SENSOR NO.1
3 6 7 5
4 H 1AG APP SENSOR NO.2
3 5
B 1AC APP SENSOR NO.3
3 6 7 5
G 1AD
3 6 7 5
C 1AH

PCM
WIRING HARNESS-SIDE CONNECTOR
APP SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

G E C A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
H F D B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–240
1890-1U-06H(01-02).fm 241 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 8.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the APP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction? 01-02
4 INSPECT APP SENSOR NO.2 Yes Replace the accelerator pedal, then go to Step 8.
• Inspect APP sensor No.2. (See 01-13-8 ACCELERATOR PEDAL REMOVAL/
(See 01-40-14 ACCELERATOR PEDAL INSTALLATION [MZI-3.5].)
POSITION (APP) SENSOR INSPECTION No Go to the next step.
[MZI-3.5].)
• Is there any malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT APP SENSOR NO.2 CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch off.
• Inspect for continuity between the following
terminals (wiring harness-side).
— APP sensor terminal F and PCM terminal
1BA.
— APP sensor terminal D and PCM terminal
1Y.
— APP sensor terminal G and PCM terminal
1AD.
— APP sensor terminal C and PCM terminal
1AH.
— APP sensor terminal H and PCM terminal
1AG.
• Are there continuity?
7 INSPECT APP SENSOR NO.2 SIGNAL CIRCUIT Yes Repair or replace suspected part, then go to Step 8.
FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals (wiring harness-side).
— APP sensor terminal F and body ground.
— APP sensor terminal D and body ground.
— APP sensor terminal G and body ground.
— APP sensor terminal C and body ground.
— APP sensor terminal H and body ground.
• Are there voltage B+?
8 VERIFY TROUBLESHOOTING OF DTC P2128 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–241
1890-1U-06H(01-02).fm 242 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2132 [MZI-3.5]
id0102d1875200

DTC P2132 APP sensor No.3 circuit low input

DETECTION
• APP sensor No.3 is out of self-test range low.
CONDITION
• Short to ground circuit between APP sensor terminal F and PCM terminal 1BA
• Short to ground circuit between APP sensor terminal D and PCM terminal 1Y
• Short to ground circuit between APP sensor terminal G and PCM terminal 1AD
POSSIBLE
• Short to ground circuit between APP sensor terminal C and PCM terminal 1AH
CAUSE
• Short to ground circuit between APP sensor terminal B and PCM terminal 1AC
• Connector or terminal malfunction
• APP sensor malfunction
APP SENSOR PCM
3 4 6
F 1BA
3 4 6
D 1Y
3 6
E 1AK APP SENSOR NO.1
3 6
5 H 1AG APP SENSOR NO.2

3 4 6
B 1AC APP SENSOR NO.3
3 4 6
G 1AD
3 4 6
C 1AH

PCM
WIRING HARNESS-SIDE CONNECTOR
APP SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

G E C A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
H F D B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

01-02–242
1890-1U-06H(01-02).fm 243 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 7.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the APP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
4 INSPECT APP SENSOR NO.3 CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 7.
SHORT TO GROUND No Go to the next step.
• Turn the ignition switch off.
• Inspect for continuity between the following
terminals:
— APP sensor terminal F and body ground.
— APP sensor terminal D and body ground.
— APP sensor terminal G and body ground.
— APP sensor terminal C and body ground.
— APP sensor terminal B and body ground.
• Are there continuity?
5 INSPECT APP SENSOR NO.3 Yes Replace the accelerator pedal, then go to Step 7.
• Inspect APP sensor No.3. (See 01-13-8 ACCELERATOR PEDAL REMOVAL/
(See 01-40-14 ACCELERATOR PEDAL INSTALLATION [MZI-3.5].)
POSITION (APP) SENSOR INSPECTION No Go to the next step.
[MZI-3.5].)
• Is there any malfunction?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
7 VERIFY TROUBLESHOOTING OF DTC P2132 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–243
1890-1U-06H(01-02).fm 244 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2133 [MZI-3.5]
id0102d1875300

DTC P2133 APP sensor No.3 circuit high input

DETECTION
• APP sensor No.3 is out of self-test range high.
CONDITION
• Open circuit wiring harness between APP sensor terminal F and PCM terminal 1BA
• Open circuit wiring harness between APP sensor terminal D and PCM terminal 1Y
• Open circuit wiring harness between APP sensor terminal G and PCM terminal 1AD
• Open circuit wiring harness between APP sensor terminal C and PCM terminal 1AH
• Open circuit wiring harness between APP sensor terminal B and PCM terminal 1AC
POSSIBLE • Short to power supply in wiring harness between APP sensor terminal F and PCM terminal 1BA
CAUSE • Short to power supply in wiring harness between APP sensor terminal D and PCM terminal 1Y
• Short to power supply in wiring harness between APP sensor terminal G and PCM terminal 1AD
• Short to power supply in wiring harness between APP sensor terminal C and PCM terminal 1AH
• Short to power supply in wiring harness between APP sensor terminal B and PCM terminal 1AC
• Connector or terminal malfunction
• APP sensor malfunction

APP SENSOR PCM

3 6 7 5
F 1BA
3 6 7 5
D 1Y

3 5
E 1AK APP SENSOR NO.1
3 5
5 H 1AG APP SENSOR NO.2

3 6 7 5
B 1AC APP SENSOR NO.3
3 6 7 5
G 1AD
3 6 7 5
C 1AH

PCM
WIRING HARNESS-SIDE CONNECTOR
APP SENSOR
WIRING HARNESS-SIDE CONNECTOR
1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A
1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

G E C A
1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B
H F D B
1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?

01-02–244
1890-1U-06H(01-02).fm 245 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
3 INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace suspected part, then go to Step 8.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the APP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction? 01-02
4 INSPECT APP SENSOR NO.3 Yes Replace the accelerator pedal, then go to Step 8.
• Inspect APP sensor No.3. (See 01-13-8 ACCELERATOR PEDAL REMOVAL/
(See 01-40-14 ACCELERATOR PEDAL INSTALLATION [MZI-3.5].)
POSITION (APP) SENSOR INSPECTION No Go to the next step.
[MZI-3.5].)
• Is there any malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace suspected part, then go to Step 8.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are there any malfunction?
6 INSPECT APP SENSOR NO.3 CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace suspected part, then go to Step 8.
• Turn the ignition switch off.
• Inspect for continuity between the following
terminals (wiring harness-side).
— APP sensor terminal F and PCM terminal
1BA.
— APP sensor terminal D and PCM terminal
1Y.
— APP sensor terminal G and PCM terminal
1AD.
— APP sensor terminal C and PCM terminal
1AH.
— APP sensor terminal B and PCM terminal
1AC.
• Are there continuity?
7 INSPECT APP SENSOR NO.3 SIGNAL CIRCUIT Yes Repair or replace suspected part, then go to Step 8.
FOR SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
terminals (wiring harness-side).
— APP sensor terminal F and body ground.
— APP sensor terminal D and body ground.
— APP sensor terminal G and body ground.
— APP sensor terminal C and body ground.
— APP sensor terminal B and body ground.
• Are there voltage B+?
8 VERIFY TROUBLESHOOTING OF DTC P2133 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–245
1890-1U-06H(01-02).fm 246 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2135 [MZI-3.5]
id0102d1812100

DTC P2135 TP sensor No.1/No.2 voltage correlation

DETECTION • The PCM flagged a concern indicating that TP sensor No.1 and TP sensor No.2 disagree by more than a
CONDITION calibrated limit.
• Short to power supply between TP sensor No.1 terminal F and PCM terminal 2Z
POSSIBLE • Short to power supply between TP sensor No.2 terminal C and PCM terminal 2AD
CAUSE • TP sensor circuits are shorted each other
• TP sensor malfunction
THROTTLE BODY PCM

3
D 2D

3 4 5
F 2Z TP SENSOR NO.1

3 4 5
C 2AD TP SENSOR NO.2

3
E 2AH

PCM
WIRING HARNESS-SIDE CONNECTOR
THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A
2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

F E D C B A 2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B
2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

01-02–246
1890-1U-06H(01-02).fm 247 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step. 01-02
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 INSPECT TP SENSOR RESISTANCE Yes Go to the next step.
• Turn the ignition switch off. No Replace the throttle body, then go to Step 6.
• Disconnect the throttle body connector. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
• Measure the resistance between the following INSTALLATION [MZI-3.5].)
terminals (throttle body component side).
— Throttle body terminal F and D: 700—1,800
ohms
— Throttle body terminal F and E: 1,300—
2,800 ohms
— Throttle body terminal C and D: 1,000—
2,400 ohms
— Throttle body terminal C and E: 500—1,500
ohms
— Throttle body terminal D and E: 700—2,100
ohms
• Are all the resistances within specifications?
4 INSPECT TP SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace suspected part, then go to Step 6.
SHORT TO POWER SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between the following
circuits:
— Throttle body terminal F (wiring harness-
side) and body ground.
— Throttle body terminal C (wiring harness-
side) and body ground.
• Are there voltage B+?
5 INSPECT TP SENSOR SIGNAL CIRCUITS FOR Yes Go to the next step.
SHORT EACH OTHER No Repair or replace suspected part, then go to the next step.
• Turn the ignition switch off.
• Disconnect the throttle body and PCM
connector.
• Measure resistance between throttle body
terminal F and C.
• Is the resistance more than 10 kilohms?
6 VERIFY TROUBLESHOOTING OF DTC P2135 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie
WM: DTC P21XX

01-02–247
1890-1U-06H(01-02).fm 248 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2195, P2197 [MZI-3.5]
id0102d1953200

DTC P2195 P2195: Front HO2S (RH) signal stuck lean

DTC P2197 P2197: Front HO2S (LH) signal stuck lean
DETECTION • A HO2S indicating lean at the end of a test is trying to correct for an over-rich condition. The test fails when
CONDITION the fuel control system no longer detects switching for a calibrated amount of time.
• Front HO2S malfunction
• Fuel injector malfunction
• Insufficient fuel line pressure
• Leakage exhaust gas
POSSIBLE
• Air suction at intake-air system malfunction
CAUSE
• Leakage fuel
• MAF sensor malfunction
• ECT sensor malfunction
• PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Yes Go to the next step.
• Has FREEZE FRAME DATA been recorded? No Record FREEZE FRAME DATA on the repair
order, then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Yes Perform repair or diagnosis according to the
• Is any related Service Bulletins available? available Service Bulletins.
• If the vehicle is not repaired, go to the next
step.
No Perform the PCM reprogramming procedure.
(See 01-40-7 PCM CONFIGURATION [MZI-
3.5])
Then go to the next step.
3 VERIFY RELATED PENDING CODE OR STORED DTCs Yes Go to the appropriate DTC troubleshooting.
• Turn the ignition switch off then to the ON position (See 01-02-12 DTC TABLE [MZI-3.5].)
(Engine off). No Go to the next step.
• Verify the related PENDING CODE or stored DTCs using
the M-MDS.
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME DATA Yes Go to the next step.
• Is DTC P2195 or P2197 on the FREEZE FRAME DATA? No Go to the troubleshooting for the DTC on the
FREEZE FRAME DATA.
(See 01-02-12 DTC TABLE [MZI-3.5].)
5 VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to the next step.
• Connect the M-MDS to the DLC-2. No Inspect the malfunctioning part according to
• Verify the following PIDs. the inspection results.
• (See 01-40-5 PCM INSPECTION [MZI-3.5].) Then go to Step 13.
— APP1
— APP2
— APP3
— ECT
— MAF
— TP_REL
— VSS
• Are the PIDs normal?
6 VERIFY CURRENT INPUT SIGNAL STATUS UNDER Yes Go to the next step.
FREEZE FRAME DATA CONDITION No Inspect the malfunctioning part according to
• Connect the M-MDS to the DLC-2. the inspection results. Then go to Step 13.
• Verify the following PIDs under the FREEZE FRAME
DATA condition.
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
— APP1
— APP2
— APP3
— ECT
— MAF
— TP_REL
• Are the PIDs normal?

01-02–248
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
7 INSPECT INTAKE AIR SYSTEM FOR EXCESSIVE AIR Yes Repair or replace the malfunctioning part,
SUCTION then go to Step 13.
• Visually inspect for looseness, cracks or damage to the No Go to the next step.
hoses in the intake-air system.
• Is there any malfunction?
8 VERIFY CURRENT INPUT SIGNAL STATUS OF MAF Yes Go to the next step.
SENSOR No Replace the MAF/IAT sensor, then go to Step 01-02
• Connect the M-MDS to the DLC-2. 13.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly according to the
engine speed.
• Is the PID normal?
9 INSPECT FRONT HO2S Yes Replace the malfunctioning HO2S, then go to
• Inspect the front HO2S (RH) (with DTC P2195) or the Step 13.
front HO2S (LH) (with DTC P2197). No Go to the next step.
(See 01-40-21 FRONT HEATED OXYGEN SENSOR
(HO2S) INSPECTION [MZI-3.5].)
• Is there any malfunction?
10 INSPECT FUEL INJECTOR Yes Replace the suspected fuel injector, then go
• Inspect the fuel injector for the right bank (with DTC to Step 13.
P2195) or the left bank (with DTC P2197). (See 01-14-23 FUEL INJECTOR REMOVAL/
(See 001-14-25 FUEL INJECTOR INSPECTION [MZI- INSTALLATION [MZI-3.5].)
3.5].) No Go to the next step.
• Is there any malfunction?
11 INSPECT FUEL LINE PRESSURE Yes Go to the next step.
• Perform the “FUEL LINE PRESSURE INSPECTION”. No Go to Step 13.
(See 01-14-6 FUEL LINE PRESSURE INSPECTION
[MZI-3.5].)
• Is there any malfunction?
12 INSPECT FUEL SYSTEM FOR FUEL LEAKAGE Yes Repair or replace the malfunctioning part,
• Visually inspect for fuel leakage in the fuel system. then go to the next step.
• Is there fuel leakage? No Replace the fuel pump unit, then go to the
next step.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
13 VERIFY TROUBLESHOOTING OF DTC P2195, P2197 Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/
• Verify that all disconnected connectors are reconnected. INSTALLATION [MZI-3.5].)
• Turn the ignition switch to the ON position (Engine off). No Go to the next step.
• Clear the DTC from the PCM memory using the M-MDS.
• Perform no load racing at the engine speed of 2,500—
3,500 rpm for 60s or more, then idle the engine for 60s or
more.
• Perform the KOEO and KOER self-test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
14 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE [MZI-3.5].) No Troubleshooting completed.
• Are any DTC present?

End Of Sie

01-02–249
1890-1U-06H(01-02).fm 250 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2196, P2198 [MZI-3.5]
id0102d1953300

DTC P2196 P2196: Front HO2S (RH) signal stuck rich

DTC P2198 P2198: Front HO2S (LH) signal stuck rich
DETECTION • A HO2S indicating rich at the end of a test is trying to correct for an over-rich condition. The test fails when
CONDITION the fuel control system no longer detects switching for a calibrated amount of time
POSSIBLE • Front HO2S malfunction
CAUSE • Fuel injector malfunction
• Insufficient fuel line pressure
• Leakage exhaust gas
• Air suction at intake-air system malfunction
• Leakage fuel
• MAF sensor malfunction
• ECT sensor malfunction
• PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the
AVAILABILITY available Service Bulletins.
• Verify related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Perform the PCM reprogramming procedure.
• Is any related Service Bulletins available? Then go to the next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify the related PENDING CODE or
stored DTCs using the M-MDS.
4 IDENTIFY TRIGGER DTC FOR FREEZE Yes Go to the next step.
FRAME DATA No Go to the troubleshooting for the DTC on the
• Is DTC P2196 or P2198 on the FREEZE FREEZE FRAME DATA.
FRAME DATA? (See 01-02-12 DTC TABLE [MZI-3.5].)
5 VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to the next step.
• Connect the M-MDS to the DLC-2. No Inspect the malfunctioning part according to the
• Verify the following PIDs. inspection results.
(See 01-40-5 PCM INSPECTION [MZI- Then go to Step 11.
3.5].)
— APP1
— APP2
— APP3
— ECT
— MAF
— TP_REL
— VSS
• Are the PIDs normal?
6 VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to the next step.
UNDER FREEZE FRAME DATA CONDITION No Inspect the malfunctioning part according to the
• Connect the M-MDS to the DLC-2. inspection results. Then go to Step 11.
• Verify the following PIDs under the FREEZE
FRAME DATA condition.
(See 01-40-5 PCM INSPECTION [MZI-
3.5].)
— APP1
— APP2
— APP3
— ECT
— MAF
— TP_REL
— VSS
• Are the PIDs normal?

01-02–250
1890-1U-06H(01-02).fm 251 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
7 VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to the next step.
OF MAF SENSOR No Replace the MAF/IAT sensor, then go to Step 11.
• Connect the M-MDS to the DLC-2.
• Start the engine.
• Access the MAF PID.
• Verify that the MAF PID changes quickly
according to engine speed. 01-02
• Is the PID normal?
8 INSPECT FRONT HO2S Yes Replace the malfunctioning HO2S, then go to Step
• Inspect the front HO2S (RH) (with DTC 11.
P2195) or the front HO2S (LH) (with DTC No Go to the next step.
P2197).
(See 01-40-21 FRONT HEATED OXYGEN
SENSOR (HO2S) INSPECTION [MZI-3.5].)
• Is there any malfunction?
9 INSPECT FUEL INJECTOR Yes Replace the suspected fuel injector, then go to Step
• Inspect the fuel injector for the right bank 11.
(with DTC P2196) or the left bank (with DTC (See 01-14-23 FUEL INJECTOR REMOVAL/
P2198). INSTALLATION [MZI-3.5].)
(See 01-14-25 FUEL INJECTOR No Go to the next step.
INSPECTION [MZI-3.5].)
• Is there any malfunction?
10 INSPECT FUEL LINE PRESSURE Yes Replace the malfunctioning part. Go to the next step.
• Perform the „FUEL LINE PRESSURE No Go to the next step.
INSPECTION”.
(See 01-14-6 FUEL LINE PRESSURE
INSPECTION [MZI-3.5].)
• Is there any malfunction?
11 VERIFY TROUBLESHOOTING OF DTC Yes Replace the PCM, then go to the next step.
P2196, P2198 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors are 3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform no load racing at the engine speed
of 2,500—3,500 rpm for 60s or more, then
idle the engine for 60s or more.
• Perform KOEO and KOER self-test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC
present?
12 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR No Troubleshooting completed.
PROCEDURE [MZI-3.5].)
• Are any DTC present?

End Of Sie
WM: DTC P22XX

01-02–251
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ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2270, P2272 [MZI-3.5]
id0102d1882400

DTC P2270 P2270: Rear HO2S (RH) signal stuck lean

DTC P2272 P2272: Rear HO2S (LH) signal stuck lean
DETECTION • The downstream HO2S is forced rich and monitored by the PCM. The test fails if the PCM does not detect
CONDITION the output of the HO2S in a calibrated amount of time
POSSIBLE • Rear HO2S malfunction
CAUSE • Leakage exhaust gas

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the
AVAILABILITY available Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Perform the PCM reprogramming procedure.
• Is any related Service Bulletins available? (See 01-40-7 PCM CONFIGURATION [MZI-3.5].)
Then go to the next step.
3 VERIFY RELATED PENDING CODE OR STORED Yes Go to the appropriate DTC troubleshooting.
DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify the related PENDING CODE or stored
DTCs using the M-MDS.
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to the troubleshooting for the DTC on the
• Is DTC P2270 or P2272 on the FREEZE FRAME FREEZE FRAME DATA.
DATA? (See 01-02-12 DTC TABLE [MZI-3.5].)
5 VERIFY CURRENT INPUT SIGNAL STATUS OF Yes Go to the next step.
REAR HO2S No Visually inspect for exhaust gas leakage between
• Start the engine and warm it up completely. the TWC and the rear HO2S.
• Access the O2S12 (with P2270) or O2S22 (with • If there is no leakage, replace the rear HO2S.
P2272) PID using the M-MDS. (See 01-15-1 EXHAUST SYSTEM REMOVAL/
• Read O2S12 or O2S22 PID under following INSTALLATION [MZI-3.5].)
accelerator pedal conditions (in PARK). Then go to the next step.
• Is the PID reading normal?
— More than 0.45 V when the accelerator pedal
is suddenly depressed (rich condition).
— Less than 0.45 V just after the release of the
accelerator pedal (lean condition).
6 VERIFY TROUBLESHOOTING OF DTC P2270, Yes Replace the PCM, then go to the next step.
P2272 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION
• Verify that all disconnected connectors are [MZI-3.5].)
reconnected. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using the
M-MDS.
• Perform no load racing at the engine speed of
2,500—3,500 rpm for 60s or more, then idle the
engine for 60s or more.
• Perform the KOEO and KOER self-test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTC present?

End Of Sie

01-02–252
1890-1U-06H(01-02).fm 253 ページ ２００６年１２月１９日　火曜日　午前１０時２２分

ON-BOARD DIAGNOSTIC [MZI-3.5]

DTC P2271, P2273 [MZI-3.5]
id0102d1882500

DTC P2271 P2271: Rear HO2S (RH) signal stuck rich

DTC P2273 P2273: Rear HO2S (LH) signal stuck rich
DETECTION • The downstream HO2S is forced rich and monitored by the PCM. The test fails if the PCM does not
CONDITION detect the output of the HO2S in a calibrated amount of time.
POSSIBLE • Rear HO2S malfunction
CAUSE 01-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS Yes Go to the next step.
BEEN RECORDED No Record FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR Yes Perform repair or diagnosis according to the available
INFORMATION AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or • If the vehicle is not repaired, go to the next step.
on-line repair information availability. No Perform the PCM reprogramming procedure.
• Is any related Service Bulletins (See 01-40-7 PCM CONFIGURATION [MZI-3.5].)
available? Then go to the next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTCs (See 01-02-12 DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the No Go to the next step.
ON position (Engine off).
• Verify the related PENDING CODE or
stored DTCs using the M-MDS.
4 IDENTIFY TRIGGER DTC FOR FREEZE Yes Go to the next step.
FRAME DATA No Go to the troubleshooting for the DTC on the FREEZE
• Is DTC P2271 or P2273 on FREEZE FRAME DATA.
FRAME DATA? (See 01-02-12 DTC TABLE [MZI-3.5].)
5 VERIFY CURRENT INPUT SIGNAL Yes Go to the next step.
STATUS OF REAR HO2S No Visually inspect for the exhaust gas leakage between
• Start the engine and warm it up TWC and rear HO2S.
completely. • If there is no leakage, replace rear HO2S.
• Access the O2S12 (with P2271) or (See 01-15-1 EXHAUST SYSTEM REMOVAL/
O2S22 (with P2273) PID using the M- INSTALLATION [MZI-3.5].)
MDS. Then go to the next step.
• Read the O2S12 or O2S22 PID under
the following accelerator pedal
conditions (in PARK).
• Is the PID reading normal?
— More than 0.45 V when the
accelerator pedal is suddenly
depressed (rich condition).
— Less than 0.45 V just after the
release of the accelerator pedal (lean
condition).
6 VERIFY TROUBLESHOOTING OF DTC Yes Replace the PCM, then go to the next step.
P2271, P2273 HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-
• Verify that all disconnected connectors 3.5].)
are reconnected. No Go to the next step.
• Turn the ignition switch to the ON
position (Engine off).
• Clear the DTC from the PCM memory
using the M-MDS.
• Perform no load racing at the engine
speed of 2,500—3,500 rpm for 60s or
more, then idle the engine for 60s or
more.
• Perform the KOEO and KOER self-test.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC
present?

01-02–253
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR (See 01-02-12 DTC TABLE [MZI-3.5].)
PROCEDURE” No Troubleshooting completed.
(See 01-02-8 AFTER REPAIR
PROCEDURE [MZI-3.5].)
• Are any DTC present?

End Of Sie
DTC P260F [MZI-3.5]
WM: DTC P26XX

id0102d1600100

DTC P260F Evaporative emission system monitoring processor performance

DETECTION • This DTC sets when a concern is detected internal to the PCM. The microprocessor that controls the
CONDITION engine off natural vacuum (EONV) leak check monitor is separate from the main processor within the PCM.
• Module communications network concerns
POSSIBLE
• PCM calibration level
CAUSE
• PCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has FREEZE FRAME DATA been recorded? to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY Service Bulletins.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related Service Bulletins available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.(See 01-02-12
STORED DTCs DTC TABLE [MZI-3.5].)
• Turn the ignition switch off then to the ON No Go to the next step
position (Engine off).
• Verify the related PENDING CODE or stored
DTCs using the M-MDS.
4 INSPECT THE PERFORMANCE OF THE Yes Go to Step 6.
PROCESSOR No Go to the next step.
• Turn the ignition switch off.
• Disconnect the battery and wait for 1 min.
• Connect the battery.
• Start the engine and warm it up completely.
• Allow the engine idle to stabilize.
• Access FTP PID.
• Is the pressure equal to 0 kPa {0 kgf/cm2, 2.0
psi}.
5 INSPECT FOR SELF-TEST DTC P260F Yes Go to the next step.
• Idle the engine 2 min. No Troubleshooting completed.
• Perform the KOEO/KOER self-test.
• Is DTC P260F present?
6 INSPECT PCM FOR THE LATEST Yes Go to the next step.
CALIBRATION No Troubleshooting completed.
• Program the PCM to the latest calibration.
• Turn the ignition switch to the ON position
(Engine running).
• Idle the engine for 2 min.
• Perform the KOEO/KOER self-test.
• Is DTC P260F present?
7 INSPECT FOR CORRECT PCM OPERATION Yes Go to the next step.
• Disconnect all the PCM connectors. No The system is correctly. Go to the next step.
• Visually inspect for:
— Pushed out pins
— Corrosion
• Connect all the PCM connectors and verify that
they seat correctly.
• Retrieve DTCs using the M-MDS.
• Is the PENDING CODE for this DTC present?

01-02–254
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ON-BOARD DIAGNOSTIC [MZI-3.5]

STEP INSPECTION ACTION
8 VERIFY TROUBLESHOOTING OF DTC P260F Yes Replace the PCM, then go to the next step.
HAS BEEN COMPLETED (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
• Verify that all disconnected connectors No Go to the next step.
reconnected.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the KOEO or KOER self-test using the 01-02
M-MDS.
(See 01-02-8 KOEO/KOER SELF TEST [MZI-
3.5].)
• Is the PENDING CODE for the DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform “AFTER REPAIR PROCEDURE”. (See 01-02-12 DTC TABLE [MZI-3.5].)
(See 01-02-8 AFTER REPAIR PROCEDURE No Troubleshooting completed.
[MZI-3.5].)
• Are any DTCs present?

End Of Sie

01-02–255
1890-1U-06H(01-03).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

01-03 SYMPTOM TROUBLESHOOTING [MZI-3.5]
FOREWORD [MZI-3.5] . . . . . . . . . . . . . . 01-03–2 NO.20 FUEL ODOR (IN ENGINE
ENGINE SYMPTOM COMPARTMENT) [MZI-3.5] . . . . . . . . . . 01-03–47
TROUBLESHOOTING [MZI-3.5] . . . . . . 01-03–3 NO.21 ENGINE NOISE [MZI-3.5] . . . . . . . 01-03–48
QUICK DIAGNOSTIC CHART NO.22 VIBRATION CONCERNS
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–5 (ENGINE) [MZI-3.5] . . . . . . . . . . . . . . . . 01-03–49
NO.1 MELTING OF MAIN OR OTHER NO.23 A/C DOES NOT WORK 01-03
FUSES [MZI-3.5] . . . . . . . . . . . . . . . . . . 01-03–9 SUFFICIENTLY [MZI-3.5] . . . . . . . . . . . . 01-03–49
NO.2 MIL ILLUMINATES [MZI-3.5] . . . . . 01-03–11 NO.24 A/C IS ALWAYS ON OR
NO.3 WILL NOT CRANK [MZI-3.5]. . . . . 01-03–11 A/C COMPRESSOR RUNS
NO.4 HARD TO START/LONG CONTINUOUSLY [MZI-3.5] . . . . . . . . . . 01-03–50
CRANK/ERRATIC START/ERRATIC NO.25 A/C DOES NOT CUT OFF
CRANK [MZI-3.5] . . . . . . . . . . . . . . . . . 01-03–14 UNDER WIDE OPEN THROTTLE
NO.5 ENGINE STALLS-AFTER CONDITIONS [MZI-3.5] . . . . . . . . . . . . . 01-03–51
START/AT IDLE [MZI-3.5] . . . . . . . . . . . 01-03–16 NO.26 EXHAUST SULPHUR SMELL
NO.6 CRANKS NORMALLY BUT WILL [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-03–52
NOT START [MZI-3.5] . . . . . . . . . . . . . . 01-03–20 NO.27 FUEL REFILL CONCERNS
NO.7 SLOW RETURN TO IDLE [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-03–53
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–24 NO.28 FUEL FILLING SHUT OFF
NO.8 ENGINE RUNS ROUGH/ROLLING CONCERNS [MZI-3.5] . . . . . . . . . . . . . . 01-03–54
IDLE [MZI-3.5] . . . . . . . . . . . . . . . . . . . . 01-03–25 NO.29 SPARK PLUG CONDITION
NO.9 FAST IDLE/RUNS ON [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-03–55
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–28 INTERMITTENT CONCERN
NO.10 LOW IDLE/STALLS DURING TROUBLESHOOTING [MZI-3.5] . . . . . . 01-03–58
DECELERATION [MZI-3.5] . . . . . . . . . . 01-03–29 Vibration Method . . . . . . . . . . . . . . . . . . 01-03–58
NO.11 ENGINE STALLS/QUITS, Water Sprinkling Method . . . . . . . . . . . . 01-03–59
ENGINE RUNS ROUGH, MISSES, ENGINE CONTROL SYSTEM
BUCK/JERK, HESITATION/STUMBLE, OPERATION INSPECTION
SURGES [MZI-3.5] . . . . . . . . . . . . . . . . 01-03–30 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-03–60
NO.12 LACK/LOSS OF Input Signal System Inspection
POWER-ACCELERATION/CRUISE Procedure . . . . . . . . . . . . . . . . . . . . . . 01-03–60
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–34 Main Relay Operation Inspection . . . . . 01-03–62
NO.13 KNOCKING/ Electronic Throttle Control System
PINGING-ACCELERATION/CRUISE Inspection . . . . . . . . . . . . . . . . . . . . . . 01-03–63
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–37 Fuel Injector
NO.14 POOR FUEL ECONOMY Operation Inspection . . . . . . . . . . . . . . 01-03–64
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–38 Fuel Cut Control
NO.15 EMISSION COMPLIANCE System Inspection. . . . . . . . . . . . . . . . 01-03–64
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–40 Fuel Pump Operation Inspection. . . . . . 01-03–64
NO.16 HIGH OIL Fuel Pump Control
CONSUMPTION/LEAKAGE System Inspection. . . . . . . . . . . . . . . . 01-03–65
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–42 Spark Test . . . . . . . . . . . . . . . . . . . . . . . 01-03–65
NO.17 COOLING SYSTEM Purge Control
CONCERNS-OVERHEATING System Inspection. . . . . . . . . . . . . . . . 01-03–66
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–42 A/C Cut-off Control
NO.18 COOLING SYSTEM System Inspection. . . . . . . . . . . . . . . . 01-03–66
CONCERNS-RUNS COLD Cooling Fan Control
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–44 System Inspection. . . . . . . . . . . . . . . . 01-03–67
NO.19 EXHAUST SMOKE Variable Valve Timing Control
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-03–45 System Operation Inspection . . . . . . . 01-03–67
Evaporative Emission (EVAP)
System Leak Inspection . . . . . . . . . . . 01-03–68

End of Toc
WM: SYMPTOM TROUBLESHOOTING (ENGINE CONTROL SYSTEM)

01-03–1
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

FOREWORD [MZI-3.5]
id0103d1800300
• When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL) indication and
diagnostic trouble code (DTC), then diagnose the malfunction according to the following flowchart:
— If a DTC exists, diagnose the applicable DTC inspection. (See 01-02-12 DTC TABLE [MZI-3.5].)
— If no DTC exists and the MIL does not illuminate or flash, diagnose the applicable symptom
troubleshooting. (See 01-03-5 QUICK DIAGNOSTIC CHART [MZI-3.5].)

CUSTOMER ARRIVES

WARNING LIGHT* NO WARNING LIGHT*

ON/FLASHING WITH SYMPTOM

CHECK FOR •CHECK DTC

PRIORITIZED DTC •IGNITION ON TEST, IDLING TEST
DTC
WITHOUT DTC

DIAGNOSE BY DTC DIAGNOSE BY SYMPTOM

(ON-BOARD DIAGNOSTIC) (SYMPTOM TROUBLESHOOTING)
•DTC TABLE 1. DIAGNOSTIC INDEX
•DTC 2. QUICK DIAGNOSIS CHART
TROUBLESHOOTING 3. SYMPTOM TROUBLESHOOTING
FLOW

ac9uuw00001101

*: Malfunction Indicator Lamp (MIL), Generator Warning Light, Security Light

End Of Sie

01-03–2
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5]
id0103d1800500
• Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.
Diagnostic Index
No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
(See 01-03-9 NO.1
1 Melting of main or other fuses — MELTING OF MAIN OR
OTHER FUSES [MZI-3.5].)
01-03
(See 01-03-11 NO.2 MIL
2 MIL illuminates The MIL is illuminated incorrectly.
ILLUMINATES [MZI-3.5].)
(See 01-03-11 NO.3 WILL
3 Will not crank The starter does not work.
NOT CRANK [MZI-3.5].)
(See 01-03-14 NO.4
The starter cranks the engine at normal HARD TO START/LONG
Hard to start/long crank/erratic start/
4 speed but the engine requires excessive CRANK/ERRATIC START/
erratic crank
cranking time before starting. ERRATIC CRANK [MZI-
3.5].)
(See 01-03-16 NO.5
The engine stops unexpectedly at idle and/or
5 Engine stalls. After start/at idle ENGINE STALLS-AFTER
after start or both.
START/AT IDLE [MZI-3.5].)
(See 01-03-20 NO.6
The starter cranks engine at normal speed CRANKS NORMALLY
6 Cranks normally but will not start
but the engine will not run. BUT WILL NOT START
[MZI-3.5].)
(See 01-03-24 NO.7
The engine takes more time than normal to
7 Slow return to idle SLOW RETURN TO IDLE
return to idle speed.
[MZI-3.5].)
The engine speed fluctuates between the (See 01-03-25 NO.8
8 Engine runs rough/rolling idle specified idle speed and lower speed and the ENGINE RUNS ROUGH/
engine shakes excessively. ROLLING IDLE [MZI-3.5].)
The engine speed continues at fast idle after
warm-up. (See 01-03-28 NO.9 FAST
9 Fast idle/runs on
The engine runs after the ignition switch is IDLE/RUNS ON [MZI-3.5].)
turned off.
(See 01-03-29 NO.10
The engine stops unexpectedly at the
LOW IDLE/STALLS
10 Low idle/stalls during deceleration beginning of deceleration or recovery from
DURING DECELERATION
deceleration.
[MZI-3.5].)
The engine stops unexpectedly at the
beginning of acceleration or during
Engine stalls/quits. Acceleration/cruise acceleration.
The engine stops unexpectedly while
cruising.
The engine speed fluctuates during (See 01-03-30 NO.11
Engine runs rough. Acceleration/cruise ENGINE STALLS/QUITS,
acceleration or cruising.
The engine misses during acceleration or ENGINE RUNS ROUGH,
11 Misses Acceleration/cruise
cruising. MISSES, BUCK/JERK,
HESITATION/STUMBLE,
Acceleration/cruise/ The vehicle bucks/jerks during acceleration, SURGES [MZI-3.5].)
Buck/jerk
deceleration cruising, or deceleration.
A momentary pause at the beginning of
Hesitation/stumble Acceleration
acceleration or during acceleration.
A momentary minor irregularity in engine
Surges Acceleration/cruise
output.
(See 01-03-34 NO.12
The performance is poor under load (such as LACK/LOSS OF POWER-
12 Lack/loss of power Acceleration/cruise
power down when climbing hills). ACCELERATION/CRUISE
[MZI-3.5].)
Sound is produced when the air/fuel mixture (See 01-03-37 NO.13
is ignited by something other than the spark KNOCKING/PINGING-
13 Knocking/pinging Acceleration/cruise
plug (such as hot spot in combustion ACCELERATION/CRUISE
chamber). [MZI-3.5].)
(See 01-03-38 NO.14
14 Poor fuel economy The fuel economy is unsatisfactory. POOR FUEL ECONOMY
[MZI-3.5].)

01-03–3
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
(See 01-03-40 NO.15
15 Emission compliance Fails emissions test. EMISSION COMPLIANCE
[MZI-3.5].)
(See 01-03-42 NO.16
HIGH OIL
16 High oil consumption/leakage The oil consumption is excessive.
CONSUMPTION/
LEAKAGE [MZI-3.5].)
(See 01-03-42 NO.17
COOLING SYSTEM
Cooling system The engine runs at higher than normal
17 Overheating CONCERNS-
concerns temperature/overheats.
OVERHEATING [MZI-
3.5].)
(See 01-03-44 NO.18
Cooling system The engine does not reach normal operating COOLING SYSTEM
18 Runs cold
concerns temperature. CONCERNS-RUNS COLD
[MZI-3.5].)
(See 01-03-45 NO.19
Blue, black, or white smoke from exhaust
19 Exhaust smoke EXHAUST SMOKE [MZI-
system
3.5].)
(See 01-03-47 NO.20
FUEL ODOR (IN ENGINE
20 Fuel odor (in engine compartment) Gasoline fuel smell or visible leakage
COMPARTMENT) [MZI-
3.5].)
(See 01-03-48 NO.21
21 Engine noise Engine noise from under hood ENGINE NOISE [MZI-
3.5].)
(See 01-03-49 NO.22
22 Vibration concerns (engine) Vibration from under hood or driveline VIBRATION CONCERNS
(ENGINE) [MZI-3.5].)
(See 01-03-49 NO.23 A/C
The A/C compressor magnetic clutch does
23 A/C does not work sufficiently. DOES NOT WORK
not engage when A/C is turned on.
SUFFICIENTLY [MZI-3.5].)
(See 01-03-50 NO.24 A/C
IS ALWAYS ON OR A/C
A/C is always on or A/C compressor runs The A/C compressor magnetic clutch does
24 COMPRESSOR RUNS
continuously. not disengage.
CONTINUOUSLY [MZI-
3.5].)
(See 01-03-51 NO.25 A/C
DOES NOT CUT OFF
A/C does not cut off under wide open The A/C compressor magnetic clutch does
25 UNDER WIDE OPEN
throttle conditions. not disengage under wide open throttle.
THROTTLE CONDITIONS
[MZI-3.5].)
(See 01-03-52 NO.26
26 Exhaust sulphur smell Rotten egg smell (sulphur) from exhaust EXHAUST SULPHUR
SMELL [MZI-3.5].)
(See 01-03-53 NO.27
27 Fuel refill concerns The fuel tank does not fill smoothly. FUEL REFILL
CONCERNS [MZI-3.5].)
(See 01-03-54 NO.28
28 Fuel filling shut off concerns The fuel does not shut off properly. FUEL FILLING SHUT OFF
CONCERNS [MZI-3.5].)
(See 01-03-55 NO.29
29 Spark plug condition An incorrect spark plug condition. SPARK PLUG
CONDITION [MZI-3.5].)
(See 05-03-4 SYMPTOM
Upshift/downshift AT concerns not related to engine TROUBLESHOOTING
30 AT concerns
engagement performance. ITEM TABLE [AW6A-EL,
AW6AX-EL].)

End Of Sie

01-03–4
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

QUICK DIAGNOSTIC CHART [MZI-3.5]
id0103d1800600

X: Applicable

Engine or transaxle mounts are improperly installed.

Starter motor malfunction (Mechanical or electrical)
Starter circuit including ignition switch is open.
01-03

Cruise control system operation improperly

Water and anti-freeze mixture is improper.

hoses, overflow system, thermostat, etc.)

Improper tension or damaged drive belts

Cooling system malfunction (Radiator,

Possible factor

Drive plate or flywheel are seized.

Cooling fan system malfunction

Improper engine compression
Charging system malfunction

Improper engine oil viscosity

Improper engine coolant level

Cooling fan seat is improper.

Improper engine oil level

Base engine malfunction

Improper valve timing
Low or dead battery

Hydrolocked engine

Improper dipstick
Troubleshooting item

Fuel quality
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank x x x x x x
4 Hard to start/long crank/erratic x x
start/erratic crank
5 Engine stalls. After start/at idle x x x
6 Cranks normally but will not start x x x
7 Slow return to idle x
8 Engine runs rough/rolling idle x x x
9 Fast idle/runs on x
10 Low idle/stalls during deceleration x
11 Engine stalls/quits. Acceleration/cruise x x x x
Engine runs rough. Acceleration/cruise x x x
Misses Acceleration/cruise x x x
Acceleration/cruise/ x x x
Buck/jerk
deceleration
Hesitation/stumble Acceleration x x x
Surges Acceleration/cruise x x x
12 Lack/loss of power Acceleration/cruise x x x
13 Knocking/pinging Acceleration/cruise x x
14 Poor fuel economy x x x x x
15 Emission compliance x x x x
16 High oil consumption/leakage x x x
17 Cooling system concerns Overheating x x x x x
18 Cooling system concerns Runs cold x x
19 Exhaust smoke x x x
20 Fuel odor (in engine compartment)
21 Engine noise x x x
22 Vibration concerns (engine) x x x
23 A/C does not work sufficiently.
24 A/C is always on or A/C compressor
runs continuously.
25 A/C does not cut off under WOT conditions. x
26 Exhaust sulphur smell x
27 Fuel refill concerns
28 Fuel filling shut off concerns
29 Spark plug condition x
30 AT concerns Upshift/downshift
engagement See Section 05-03 TROUBLESHOOTING

ac9uuw00001012

01-03–5
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

X: Applicable

Idle learning of electronic throttle control system is not

CKP sensor is damaged. (e.g. open or short circuits)

Vacuum leakage (Vacuum hose damage, misrouting)

Fuel pump malfunction (Mechanically or electrically)

Improper gap between CKP sensor and crankshaft
Ignition coil malfunction (e.g. open, short or cracks)
Initial ignition timing misadjustment (CKP sensor
Electronic throttle control improper operation
Air leakage from intake-air system (Loose
Variable valve timing system malfunction

Air cleaner element clogging or restriction

Possible factor

tubes, cracks, gaskets breakage)

&crankshaft pulley misadjustment)

Fuel hoses restriction or clogging

Intake air temperature is too hot

Pressure regulator malfunction

Crankshaft pulley is damaged
Erratic signal to ignition coil
Throttle body malfunction

Spark plug malfunction

Troubleshooting item Engine overheating

completed
1 Melting of main or other fuses
2 MIL illuminates x x x
3 Will not crank
4 Hard to start/long crank/erratic x x x x x x x x x x x x
start/erratic crank
5 Engine stalls. After start/at idle x x x x x x x x x x x x x x x x
6 Cranks normally but will not start x x x x x x x x x x x x x x x x
7 Slow return to idle x
8 Engine runs rough/rolling idle x x x x x x x x x x x x x x x x
9 Fast idle/runs on x x x
10 Low idle/stalls during deceleration x x x
11 Engine stalls/quits. Acceleration/cruise x x x x x x x x x x x x x x
Engine runs rough. Acceleration/cruise x x x x x x x x x x x x x x
Misses Acceleration/cruise x x x x x x x x x x x x x x
Buck/jerk Acceleration/cruise/ x x x x x x x x x x x x x x
deceleration
Hesitation/stumble Acceleration x x x x x x x x x x x x x x
Surges Acceleration/cruise x x x x x x x x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x x x x x x x x x
13 Knocking/pinging Acceleration/cruise x x x
14 Poor fuel economy x x x x x
15 Emission compliance x x x x x x x x x
16 High oil consumption/leakage
17 Cooling system concerns Overheating
18 Cooling system concerns Runs cold
19 Exhaust smoke x x x x x x x
20 Fuel odor (in engine compartment) x
21 Engine noise x x
22 Vibration concerns (engine)
23 A/C does not work sufficiently.
24 A/C is always on or A/C compressor
runs continuously.
25 A/C does not cut off under WOT conditions.
26 Exhaust sulphur smell x x x x
27 Fuel refill concerns
28 Fuel filling shut off concerns
29 Spark plug condition x x x x x x
30 AT concerns Upshift/downshift
See Section 05-03 TROUBLESHOOTING
engagement

ac9uuw00001013

01-03–6
1890-1U-06H(01-03).fm 7 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

X: Applicable

Fuel leakage from fuel system (including insulator, injector O-ring)

Injectors malfunction (Leakage or clogging, inoperative)
01-03

Main relay malfunction (Mechanically or electrically)

CMP sensor is damaged. (e.g. open or short circuit)
Possible factor

Constant voltage supply circuit malfunction

Brake switch and related circuit malfunction

PCM or sensor GND circuit open or short
Exhaust system restriction or clogging

HO2S and related circuit malfunction

Improper air/fuel mixture ratio control

Check valve (two-way) malfunction

EVAP control system malfunction

Fuel into evaporative purge hose

Fuel filters restriction or clogging

Catalytic converter malfunction

Fuel-filler cap malfunction

TR switch misadjustment
CHT sensor malfunction
PCV valve malfunction

TR switch malfunction
Camshaft is damaged
Troubleshooting item

1 Melting of main or other fuses

2 MIL illuminates x x x x x x
3 Will not crank x x
4 Hard to start/long crank/erratic x x x x x x x x x
start/erratic crank
5 Engine stalls. After start/at idle x x x x x x x x x x
6 Cranks normally but will not start x x x x x x x x x
7 Slow return to idle x
8 Engine runs rough/rolling idle x x x x x x x x x x
9 Fast idle/runs on x
10 Low idle/stalls during deceleration x x x x x
11 Engine stalls/quits. Acceleration/cruise x x x x x x x x x x x x x
Engine runs rough. Acceleration/cruise x x x x x x x x x x x x x
Misses Acceleration/cruise x x x x x x x x x x x x x
Buck/jerk Acceleration/cruise/ x x x x x x x x x x x x x
deceleration
Hesitation/stumble Acceleration x x x x x x x x x x x x x
Surges Acceleration/cruise x x x x x x x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x
13 Knocking/pinging Acceleration/cruise x x
14 Poor fuel economy x x x x x
15 Emission compliance x x x x x x x x x x
16 High oil consumption/leakage x
17 Cooling system concerns Overheating
18 Cooling system concerns Runs cold
19 Exhaust smoke x x x
20 Fuel odor (in engine compartment) x x
21 Engine noise
22 Vibration concerns (engine)
23 A/C does not work sufficiently.
24 A/C is always on or A/C compressor
runs continuously.
25 A/C does not cut off under WOT condition
26 Exhaust sulphur smell x x
27 Fuel refill concerns x
28 Fuel filling shut off concerns x
29 Spark plug condition x x x x x x x
30 AT concerns Upshift/downshift
engagement See Section 05-03 TROUBLESHOOTING

ac9uuw00001014

01-03–7
1890-1U-06H(01-03).fm 8 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

X: Applicable

A/C relay (A/C control signal circuit malfunction)

Immobilizer system or related circuit malfunction

A/C compressor magnetic clutch malfunction
Knock sensor and related circuit malfunction
MAF sensor and related circuit malfunction

Immobilizer system operating (if equipped)

IAT sensor and related circuit malfunction

TP sensor and related circuit malfunction

Accelerator pedal position sensor and

Improper refrigerant charging amount

Improper balance of wheels and tires

Condenser fan system malfunction

VSS and related circuit malfunction

Possible factor

AT related parts malfunction

related circuit malfunction

Improper load signal input

Suspension malfunction
Drive line malfunction
Improper ATF level
Brake dragging
Troubleshooting item

(if equipped)
Loose parts
1 Melting of main or other fuses
2 MIL illuminates x x x x x
3 Will not crank x x
4 Hard to start/long crank/erratic x
start/erratic crank
5 Engine stalls. After start/at idle x x x x
6 Cranks normally but will not start x x
7 Slow return to idle
8 Engine runs rough/rolling idle x x x x
9 Fast idle/runs on x
10 Low idle/stalls during deceleration x x x x x
11 Engine stalls/quits. Acceleration/cruise x x x x x x x
Engine runs rough. Acceleration/cruise x x x x x x x
Misses Acceleration/cruise x x x x x x x
Buck/jerk Acceleration/cruise/ x x x x x x x
deceleration
Hesitation/stumble Acceleration x x x x x x x
Surges Acceleration/cruise x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x
13 Knocking/pinging Acceleration/cruise x x x
14 Poor fuel economy x x x
15 Emission compliance
16 High oil consumption/leakage
17 Cooling system Overheating x x x
concerns
18 Cooling system x
Runs cold
concerns
19 Exhaust smoke
20 Fuel odor (in engine compartment)
21 Engine noise x
22 Vibration concerns (engine) x x x x
23 A/C does not work sufficiently. x x x
24 A/C is always on or A/C compressor
x x
runs continuously.
25 A/C does not cut off under WOT conditions. x
26 Exhaust sulphur smell
27 Fuel refill concerns
28 Fuel filling shut off concerns
29 Spark plug condition x
30 AT concerns Upshift/downshift
engagement See Section 05-03 TROUBLESHOOTING

ac9uuw00001015

End Of Sie

01-03–8
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
SYMPTOM TROUBLESHOOTING [MZI-3.5]
NO.1 MELTING OF MAIN OR OTHER FUSES [MZI-3.5]
id0103d1800700

1 MELTING OF MAIN OR OTHER FUSES

[TROUBLESHOOTING HINTS]
Inspect condition of fuse.

01-03

Shorted wiring harness Deterioration

Fuse Replace fuse

Repair shorted wiring harness and replace fuse

Damaged fuse Related wiring harness

MAIN MAIN fuse
• IGKEY2 fuse
• Ignition switch
• Generator
• FUEL PUMP fuse
• FAN1 fuse
— Cooling fan relay (Single fan control module)
— Fan control module (Single fan control module)
— Cooling fan relay No.1 (Dual fan control module)
— Fan control module No.1 (Dual fan control module)
• FAN2 fuse
— Cooling fan relay (Single fan control module)
— Fan control module (Single fan control module)
— Cooling fan relay No.2 (Dual fan control module)
— Fan control module No.2 (Dual fan control module)
IGKEY1 IGKEY1 fuse
• Ignition switch
• ENG.IGA fuse
IG KEY2 IGKEY2 fuse
• Ignition switch
• STA fuse
• Starter relay
— Starter
— PCM
ENG.IGA ENG.IGA fuse
• Fuel pump relay
• PCM
• Diode
• Fan relay (Single fan control module)
• Fan relay No.1 (Dual fan control module)
• Fan relay No.2 (Dual fan control module)
FUEL PUMP FUEL PUMP fuse
• Fuel pump relay
— Fuel pump
— PCM
• INJ fuse
— PCM
— Fuel injector No.1
— Fuel injector No.2
— Fuel injector No.3
— Fuel injector No.4
— Fuel injector No.5
— Fuel injector No.6

Revised 1/2007 (Ref. No. R009/07) 01-03–9

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
SYMPTOM TROUBLESHOOTING [MZI-3.5]
Damaged fuse Related wiring harness
FAN 1 FAN 1 fuse
• Fan relay
— Fan control module (Single fan control module)
• Cooling fan relay No.1 (Dual fan control module)
— Fan control module No.1 (Dual fan control module)
FAN 2 FAN 2 fuse
• Fan relay
— Fan control module (Single fan control module)
• Cooling fan relay No.2 (Dual fan control module)
— Fan control module No.2 (Dual fan control module)
ENG+B ENG+B fuse
• Generator
• CVV
• PCM
STA STA fuse
• Starter relay
— PCM
ENG BAR ENG BAR fuse
• Front HO2S (RH)
• Front HO2S (LH)
• Rear HO2S (RH)
• Rear HO2S (LH)
• Oil control valve (RH)
• Oil control valve (LH)
• Mass air flow/intake air temperature sensor
• Purge solenoid valve
• Brake switch No.2
ENG BAR2 ENG BAR2 fuse
• A/C relay
• PCV valve heater fitting
• PCV valve heater control
ENG INJ ENG INJ fuse
• PCM
INJ INJ fuse
• PCM
• Fuel injector No.1
• Fuel injector No.2
• Fuel injector No.3
• Fuel injector No.4
• Fuel injector No.5
• Fuel injector No.6
IG COIL IG COIL fuse
• Condenser
• Ignition coil No.1
• Ignition coil No.2
• Ignition coil No.3
• Ignition coil No.4
• Ignition coil No.5
• Ignition coil No.6

End Of Sie

01-03–10 Revised 1/2007 (Ref. No. R009/07)

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SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.2 MIL ILLUMINATES [MZI-3.5]
id0103d1800800

2 MIL ILLUMINATES
DESCRIPTION The MIL is illuminated incorrectly.
• The PCM illuminates for emission-related concern (DTC is stored in PCM)
• Instrument cluster malfunction
POSSIBLE CAUSE
Note 01-03
• If the MIL blinks at steady rate, misfire condition could possibly exist.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position • Go to appropriate the DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
• Inspect instrument cluster operation.
(See 09-22-5 INSTRUMENT CLUSTER
INSPECTION.)
2 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-5 PCM INSPECTION [MZI-3.5].)

End Of Sie
NO.3 WILL NOT CRANK [MZI-3.5]
id0103d1800900

3 WILL NOT CRANK

DESCRIPTION The starter does not work.
• Open starter circuit between ignition switch and starter
• TR switch malfunction
• TR switch misadjustment
• Low or dead battery
• Charging system malfunction.
POSSIBLE CAUSE
• Starter malfunction
• Seized/hydrolocked engine, drive plate
• Immobilizer system and/or circuit malfunction
• Immobilizer system operating properly. (Ignition key is not registered)
• Advanced keyless entry system malfunction

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Note Yes Inspect advanced keyless entry system and repair or
• The following test should be performed on replace according to inspection result.
the advanced keyless entry system. If not (See 09-03E-4 SYMPTOM TROUBLESHOOTING
equipped, go to the next step. CHART [KEYLESS ENTRY SYSTEM].)
No Go to the next step.
Start the engine using the mechanical ignition
key.
Does the engine start?
2 Connect the M-MDS to the DLC-2. Yes Both conditions appear:
Do the following conditions appear? Go to Step 4.
• The engine is not completely started.
• DTC P1260 is displayed.
No Either or other condition appears:
Go to the next step.
3 Turn the ignition switch to the ON position. Yes Go to the next step.
Is the coil connector securely connected to the No Connect the coil connector securely.
coil? Return to Step 1.

01-03–11
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
4 Does the security light flush? Yes Go to the next step.
No Inspect and repair or replace the following:
• Wiring harnesses and connectors from keyless
control module terminal 3W and instrument cluster
terminal 1W
• Wiring harness and connectors from keyless
control module terminal 3X and instrument cluster
terminal 1X
• Instrument cluster
(See 09-22-5 INSTRUMENT CLUSTER
INSPECTION.)
5 Connect the M-MDS to the DLC-2 and retrieve Yes Go to appropriate DTC inspection.
DTC for PCM, instrument cluster and keyless (See 01-02-12 DTC TABLE [MZI-3.5].)
control module. No Go to the next step.
DTC
PCM: B1342, U0073, U0155
Instrument cluster: B1213, B1600,
B1601,B1602, B1681, B2103, B2139,
B2431, U0100, U0214
Keyless control module (with advanced
keyless entry system): B1681, B2103,
B1213
6 Inspect for the following wiring harnesses and Yes Repair or replace suspected wiring harness and
connectors: connector.
With advanced keyless entry system No Go to the next step. (with advanced keyless entry
• Between coil terminal A and keyless control system)
module terminal 3V Go to the Step 8. (without advanced keyless entry
• Between coil terminal B and keyless control system)
module terminal 3U
Without advanced keyless entry system
• Between coil terminal A and instrument
cluster terminal 1G
• Between coil terminal B and instrument
cluster terminal 1E
Is there any malfunction?
7 Inspect the following wiring harnesses and Yes Repair or replace wiring harness and connectors.
connectors for an open or short circuit: No Go to the next step.
• Between keyless control module terminal 3W
and instrument cluster terminal 1W
• Between keyless control module terminal 3X
and instrument cluster terminal 1X
Is there any malfunction?
8 Inspect for the following wiring harnesses and Yes Repair or replace suspected wiring harness and
connectors: connector.
• Between PCM terminal 1BG and instrument No Go to the next step.
cluster terminal 1W
• Between PCM terminal 1BL and instrument
cluster terminal 1X
Is there any malfunction?
9 Is there continuity between PCM terminal 1BR Yes Go to the next step.
and starter relay with P or N position? No Repair or replace wiring harness.
10 Inspect the following: Yes Go to the next step.
• Battery connection No Service if necessary.
• Battery condition Repeat Step 9.
• Transaxle is in Park or Neutral.
• Fuses
Are all items normal?
11 Is clicking sound heard from starter when the Yes Go to the next step.
ignition switch is turned to START? No Go to Step 13.
12 Inspect the starting system. Yes Inspect for seized/hydrolocked engine, flywheel or drive
(See 01-19-2 STARTER INSPECTION [MZI- plate.
3.5].) No Repair or replace components if required.
Is starting system normal?

01-03–12
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
13 Do any other electrical accessories function? Yes Go to the next step.
No Inspect the charging system.
(See 01-17-2 BATTERY INSPECTION [MZI-3.5].)
(See 01-17-5 GENERATOR INSPECTION [MZI-3.5].)
14 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access TR PID. No Inspect adjustment of TR switch.
Turn the ignition switch to the ON position. If TR switch is adjusted properly, inspect starter. 01-03
Is TR PID indicated P/N when selecting P or N
position?
15 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs. Communication error message is displayed:
Are there any DTCs displayed? Inspect for the following:
• Open circuit in wiring harness between main
relay and PCM terminal 1BO or 1BJ
• Open circuit in wiring harness between main
relay terminal E and PCM terminal 1BM
• Main relay is stuck open.
• Open or short circuit in wiring harness between
the DLC-2 and PCM terminals 1BL or 1BG
• Open or poor GND circuit (PCM terminal 1D, 1J,
1BP, 1BK)
• Poor connection of vehicle body GND
No No DTC is displayed:
Inspect the following:
• START circuit in ignition switch
• Open circuit in wiring harness between ignition
switch and starter
16 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–13
1890-1U-06H(01-03).fm 14 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK [MZI-3.5]
id0103d1801000

4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK

• The starter cranks engine at normal speed but engine requires excessive cranking time before
DESCRIPTION starting.
• The battery is in normal condition.
• Erratic signal to ignition coil
• Vacuum leakage
• Poor fuel quality
• Starting system malfunction
• Spark plug malfunction
• Air leakage from intake-air system
• Erratic signal from CKP sensor
• Erratic signal from CMP sensor
• Improper air/fuel mixture ratio control
• Air cleaner restriction
• Improper operation of electronic throttle control system
• PCV valve malfunction
• Inadequate fuel pressure
• Purge solenoid valve malfunction
• MAF sensor contamination
• Incorrect MAF sensor GND voltage
• Restriction in exhaust system
POSSIBLE CAUSE • Pressure regulator malfunction (built-in fuel pump unit)

Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
"BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Inspect for the following: Yes Go to the next step.
• Vacuum leakage No Service if necessary.
• Proper fuel quality (such as proper octane, Repeat Step 1.
contamination, winter/summer blend)
• Loose bands on intake-air system
• Cracks on intake-air system parts
• Intake-air system restriction (such as air
cleaner element, fresh air duct.)
Are all items normal?
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
3 Is engine overheating? Yes Go to symptom troubleshooting “No.17 Cooling system
concerns-Overheating”.
(See 01-03-42 NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [MZI-3.5].)
No Go to the next step.
4 Inspect the ignition coil related wiring harness Yes Go to the next step.
condition (intermittent open or short circuit) for No Repair the wiring harnesses.
all cylinders.
Are wiring harness conditions normal?

01-03–14
1890-1U-06H(01-03).fm 15 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
5 Inspect the spark plug conditions. Yes Spark plug is wet or covered with carbon:
Is spark plug wet, covered with carbon or grayish Inspect for fuel leakage from fuel injector.
white? Spark plug is grayish white:
Inspect the fuel injector for clogging.
No Install the spark plugs on original cylinders.
Go to the next step.
6 Visually inspect the CKP sensor and teeth of Yes Go to the next step. 01-03
crankshaft pulley. No Replace the malfunctioning part.
Are the CKP sensor and teeth of crankshaft
pulley normal?
7 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace the PCV valve.
8 Attempt to start engine at part throttle. Yes Inspect the electronic throttle control system operation.
Does engine run smoothly at part throttle? (See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
No Go to the next step.
9 Install the fuel pressure gauge between the fuel Yes Go to the next step.
pipe and fuel distributor. No Zero or low:
Short check connector terminal F/P to body
Inspect the fuel pump relay and the fuel pump circuit.
GND using a jumper wiring.
Inspect the fuel line for clogging.
Turn the ignition switch to the ON position.
If there is no malfunction, replace the fuel pump
Is fuel line pressure correct with ignition switch
unit.
ON?
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
(See 01-14-6 FUEL LINE PRESSURE
INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
10 Is the fuel line pressure held after ignition switch Yes Go to the next step.
is turned off? No Inspect the fuel injector.
(See 01-14-6 FUEL LINE PRESSURE (See 01-14-25 FUEL INJECTOR INSPECTION [MZI-
INSPECTION [MZI-3.5].) 3.5].)
If the fuel injector is normal, replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
11 Disconnect a vacuum hose from purge solenoid Yes Inspect if the purge solenoid valve is stuck open.
valve and plug opening end of vacuum hose. No Go to the next step.
Start engine.
Is starting condition improved?
12 Inspect the MAF sensor for following: Yes Repair or replace the malfunctioning part.
• Contamination No Go to the next step.
• MAF sensor terminal B voltage (GND circuit)
Is there any contamination?
13 Visually inspect the exhaust system part. Yes Replace the suspected part.
Is there any deformed exhaust system part? No Go to the next step.
14 Inspect the starting system. Yes Inspect for loose connectors or poor terminal contact.
(See 01-19-2 STARTER INSPECTION [MZI- No Repair or replace components as required.
3.5].)
Is starting system normal?
15 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, Replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–15
1890-1U-06H(01-03).fm 16 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.5 ENGINE STALLS-AFTER START/AT IDLE [MZI-3.5]
id0103d1801100

5 ENGINE STALLS—AFTER START/AT IDLE

DESCRIPTION • Engine stops unexpectedly.
• A/C system operation is improper
• Air leakage from intake-air system parts
• Purge solenoid valve malfunction
• Improper operation of electronic throttle control system
• No signal from CKP sensor due to sensor, related wire or wrong installation
• Vacuum leakage
• Engine overheating
• Low engine compression
• Erratic signal to ignition coil
• Poor fuel quality
• PCV valve malfunction
• Air cleaner restriction
• Restriction in exhaust system
• Electrical connector disconnection
• Open or short circuit in fuel pump body and related wiring harness
• No battery power supply to PCM or poor GND
• Inadequate fuel pressure
• Fuel pump body mechanical malfunction
• Fuel leakage from fuel injector
• Fuel injector clogging
• Ignition coil malfunction
• Improper air/fuel mixture ratio control
POSSIBLE CAUSE • Improper valve timing
• Improper operation variable valve timing control system
• Immobilizer system and/or circuit malfunction
• Immobilizer system operating property. (Ignition key is not registered.)
• Pressure regulator malfunction (built-in fuel pump unit)

Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes Both conditions appear:
Do the following conditions appear? Go to Step 3.
• The engine is not completely started.
• DTC P1260 is displayed.
No Either or other condition appears:
Go to the next step.
2 Does the engine stall after approx. 2 s since the Yes Go to the next step.
engine is started? No Immobilizer system is normal.
Go to Step 8.
3 Is coil connector securely connected to coil? Yes Go to the next step.
No Connect the coil connector securely.
Return to Step 2.

01-03–16
1890-1U-06H(01-03).fm 17 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
4 Does the security light flush? Yes Go to the next step.
No Inspect and repair or replace the following:
• Wiring harnesses and connectors from keyless
control module terminal 3W and instrument cluster
terminal 1W
• Wiring harness and connectors from keyless
control module terminal 3X and instrument cluster 01-03
terminal 1X
• Instrument cluster
(See 09-22-5 INSTRUMENT CLUSTER
INSPECTION.)
5 Connect the M-MDS to the DLC-2 and retrieve Yes Go to the appropriate DTC inspection.
DTC for PCM, instrument cluster and keyless (See 01-02-12 DTC TABLE [MZI-3.5].)
control module (with advanced keyless entry No Go to the next step.
system).
Are any of the following DTCs displayed?
DTC
PCM: B1342, U0073, U0155
Instrument cluster: B1213, B1600, B1601,
B1602, B1681, B2103, 2139, B2431,
U0110, U0214
Keyless control module (with advanced
keyless entry system): B1681, B2103,
B1213
6 Inspect for the following wiring harnesses and Yes Repair or replace the suspected wiring harness and
connectors: connector.
With advanced keyless entry system: No Go to the next step. (with advanced keyless entry
• Between coil terminal A and keyless control system.)
module terminal 3V Go to Step 8. (without advanced keyless entry system.)
• Between coil terminal B and keyless control
module terminal 3U
Without advanced keyless entry system:
• Between coil terminal A and instrument
cluster terminal 1G
• Between coil terminal B and instrument
cluster terminal 1E
Is there any malfunction?
7 Inspect the following wiring harnesses and Yes Repair or replace wiring harness and connectors.
connectors for an open or short circuit: No Go to the next step.
• Between keyless control module terminal 3W
and instrument cluster terminal 1W
• Between keyless control module terminal 3X
and instrument cluster terminal 1X
Is there any malfunction?
8 Inspect for the following wiring harnesses and Yes Repair or replace the suspected wiring harness and
connectors: connector.
• Between PCM terminal 1BG and instrument No Go to the next step.
cluster terminal 1W
• Between PCM terminal 1BL and instrument
cluster terminal 1X
Is there any malfunction?
9 Verify the following: Yes Go to the next step.
• Vacuum connection No Service if necessary.
• Air cleaner element Repeat Step 9.
• No air leakage from intake-air system
• No restriction of intake-air system
• Proper sealing of intake manifold and
components attached to intake manifold
• Ignition wiring
• Fuel quality: proper octane, contamination,
winter/summer blend
• Electrical connections
• Smooth operation of throttle valve
Are all items normal?

01-03–17
1890-1U-06H(01-03).fm 18 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
10 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access the APP1 and APP2, APP3 PIDs. Crank No Inspect for the following:
the engine with accelerator pedal released. • APP sensor
Are the APP1 and APP2, APP3 PIDs indicating • Wiring harnesses and connectors for following:
that the accelerator pedal is in the released — PCM terminal 1AC—APP sensor terminal B
position? — PCM terminal 1AH—APP sensor terminal C
— PCM terminal 1Y—APP sensor terminal D
— PCM terminal 1AK—APP sensor terminal E
— PCM terminal 1BA—APP sensor terminal F
— PCM terminal 1AD—APP sensor terminal G
— PCM terminal 1AG—APP sensor terminal H
11 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access the TP1, TP2 PID. Crank the engine with No Inspect for the following:
accelerator pedal released. • TP sensor
Are the TP1, TP2 PID indicates the closed • Wiring harnesses and connectors for following:
throttle position? — PCM terminal 2BO—TP sensor terminal A
— PCM terminal 2BR—TP sensor terminal B
— PCM terminal 2AD—TP sensor terminal C
— PCM terminal 2D—TP sensor terminal D
— PCM terminal 2AH—TP sensor terminal E
— PCM terminal 2Z—TP sensor terminal F
12 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs. Communication error message is displayed:
Are there any DTCs displayed? Inspect for the following:
• Open circuit in wiring harness between main
relay and PCM terminal 1BO or 1BJ
• Open main relay GND circuit
• Main relay is stuck open.
• Open or short circuit in wiring harness between
the DLC-2 and PCM terminals 1BL or 1BG
• Open or poor GND circuit (PCM terminal 1D, 1J,
1BP, 1BK)
• Poor connection of vehicle body GND
No No DTC is displayed:
Go to the next step.
13 Attempt to start engine at part throttle. Yes Inspect electronic throttle control system operation.
Does engine run smoothly at part throttle? (See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
No Go to the next step.
14 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access RPM PID. No Inspect for the following:
Is RPM PID indicating engine speed during • Open or short circuit in CKP sensor
engine cranking? • Open or short circuit in wiring harness between
CKP sensor terminal A and PCM terminal 2P
• Open or short circuit in wiring harness between
CKP sensor terminal B and PCM terminal 2T
• Open or short circuit in CKP sensor wiring
harnesses
If CKP sensor and wiring harness are normal, go to the
next step.
15 Visually inspect CKP sensor and teeth of Yes Go to the next step.
crankshaft pulley. No Replace the malfunctioning part.
Are CKP sensor and teeth of crankshaft pulley
normal?
16 Inspect the ignition coil related wiring harness Yes Go to the next step.
condition (intermittent open or short circuit) for No Repair the wiring harnesses.
all cylinders. Are wiring harness conditions
normal?
17 Perform the spark test. Yes Go to the next step.
(See 01-03-60 ENGINE CONTROL SYSTEM If symptoms occurs with the A/C on, go to Step 24.
OPERATION INSPECTION [MZI-3.5].) No Repair or replace the malfunctioning part according to
Is strong blue spark visible at each cylinder? spark test result.

01-03–18
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
18 Inspect the spark plug condition. Yes Spark plug is wet or covered with carbon:
Is spark plug wet, covered with carbon or grayish Inspect for fuel leakage from injector.
white? Spark plug is grayish white:
Inspect the fuel injector for clogging.
No Install spark plugs on original cylinders.
Go to the next step.
19 Remove and shake the PCV valve. Yes Go to the next step. 01-03
Does the PCV valve rattle? No Replace the PCV valve.
20 visually inspect the exhaust system part. Yes Replace the suspected part.
Is there any deformed exhaust system part? No Go to the next step.
21 Install the fuel pressure gauge between the fuel Yes Go to the next step.
pipe and the fuel distributor. No Zero or low:
Short check connector terminal F/P to body
Inspect the fuel pump relay and fuel pump circuit.
GND using a jumper wiring.
Inspect the fuel line for clogging.
Turn the ignition switch to the ON position.
If there is no malfunction, replace the fuel pump
Is fuel line pressure correct with ignition switch
unit.
ON?
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
(See 01-14-6 FUEL LINE PRESSURE
INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
22 Visually inspect for fuel leakage at fuel injector Yes Go to the next step.
O-ring and fuel line. No Inspect the fuel injector.
Service if necessary. If the fuel injector is normal, replace the fuel pump unit.
Is fuel line pressure held after ignition switch is (See 01-14-16 FUEL PUMP UNIT REMOVAL/
turned off? INSTALLATION [MZI-3.5].)
(See 01-14-6 FUEL LINE PRESSURE
INSPECTION [MZI-3.5].)
23 Note Yes Go to the next step.
• The following test is for stall concerns with No If A/C is always on, go to symptom troubleshooting
the A/C on. If other symptoms exist, go to “No.24 A/C is always on or A/C compressor runs
the next step. continuously”.
(See 01-03-50 NO.24 A/C IS ALWAYS ON OR A/C
Connect pressure gauges to A/C low and high COMPRESSOR RUNS CONTINUOUSLY [MZI-3.5].)
pressure side lines. For other symptoms, inspect the following:
Turn A/C on and measure low side and high side • Refrigerant charging amount
pressures. • Condenser fan operation
Are pressures within specifications?
(See 07-10-6 REFRIGERANT PRESSURE
CHECK.)
24 Disconnect the vacuum hose between the purge Yes Inspect if purge solenoid valve is stuck open.
solenoid valve and the intake manifold from Inspect evaporative emission control system.
purge solenoid side. No Go to the next step.
Plug opening end of vacuum hose.
Start the engine.
Is the engine stall now eliminated?
25 Is air leakage felt or heard at intake-air system Yes Repair or replace the malfunctioning part.
components while racing the engine to higher No Go to the next step.
speed?
26 Inspect variable valve timing control system Yes Go to the next step.
operation. No Repair or replace the malfunctioning parts according to
(See 01-03-60 ENGINE CONTROL SYSTEM variable valve timing control system operation
OPERATION INSPECTION [MZI-3.5].) inspection results.
Does variable valve timing control function
properly?
27 Is the engine compression correct? Yes Inspect the valve timing.
No Inspect for cause.

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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
28 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie
NO.6 CRANKS NORMALLY BUT WILL NOT START [MZI-3.5]
id0103d1801200

6 CRANKS NORMALLY BUT WILL NOT START

• The starter cranks engine at normal speed but the engine will not run.
• Refer to symptom troubleshooting "No.5 Engine stalls" if this symptom appears after engine stall.
DESCRIPTION
• Fuel is in tank.
• Battery is in normal condition.
• No battery power supply to PCM
• Air leakage from intake-air system
• Open PCM GND or vehicle body GND
• Improper operation of electronic throttle control system
• No signal from CKP sensor due to sensor, related wire or incorrect installation
• No signal from CMP sensor due to sensor, related wire or incorrect installation
• Low engine compression
• Engine overheating
• Vacuum leakage
• Erratic signal to ignition coil
• Improper air/fuel mixture ratio control
• Poor fuel quality
• PCV valve malfunction
• Restriction in intake-air system
• Restriction in exhaust system
• Disconnected electrical connector
• Open or short circuit in fuel pump body and related wiring harness
• Inadequate fuel pressure
• Fuel pump mechanical malfunction
• Fuel leakage from injector
• Fuel injector is clogged.
• Purge solenoid valve malfunction
• Spark plug malfunction
POSSIBLE CAUSE • Ignition coil malfunction
• Improper variable valve timing control system operation
• Improper valve timing
• Immobilizer system and/or circuit malfunction
• Immobilizer system operating properly. (Ignition key is not registered.)
• Pressure regulator malfunction (built-in fuel pump unit)

Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
"BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

01-03–20
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes Both conditions appear:
Do any of the following conditions appear? Go to Step 3.
• Engine does not completely start.
• DTC P1260 is displayed.
No Either or other condition appears:
Go to the next step.
2 Does engine stall after approx. 2 s from when it Yes Go to the next step.
is started? 01-03
No Immobilizer system is normal.
Go to Step 8.
3 Is the coil connector securely connected to the Yes Go to the next step.
coil? No Connect the coil connector securely.
Return to Step 2.
4 Does the security light flush? Yes Go to the next step.
No Inspect and repair or replace the following:
• Wiring harnesses and connectors from keyless
control module terminal 3W and instrument cluster
terminal 1W
• Wiring harness and connectors from keyless
control module terminal 3X and instrument cluster
terminal 1X
• Instrument cluster
(See 09-22-5 INSTRUMENT CLUSTER
INSPECTION.)
5 Connect the M-MDS to the DLC-2 and retrieve Yes Go to the appropriate DTC inspection.
the DTC for PCM, instrument cluster and keyless (See 01-02-12 DTC TABLE [MZI-3.5].)
control module (with advanced keyless entry No Go to the next step.
system).
Are any of the following DTCs displayed?
DTC
PCM: B1342, U0073, U0155
Instrument cluster: B1213, B1600, B1601,
B1602, B1681, B2103, B2139, B2431,
U0100, U0214
Keyless control module (with advanced
keyless entry system): B1681, B2103,
B1213
6 Inspect the following wiring harnesses and Yes Repair or replace the suspected wiring harness and
connectors: connector.
With advanced keyless entry system: No Go to the next step. (with advanced keyless entry
• Between coil terminal A and keyless control system.)
module terminal 3V Go to Step 8. (without advanced keyless entry system.)
• Between coil terminal B and keyless control
module terminal 3U
Without advanced keyless entry system:
• Between coil terminal A and instrument
cluster terminal 1G
• Between coil terminal B and instrument
cluster terminal 1E
Is there any malfunction?
7 Inspect the following wiring harnesses and Yes Repair or replace wiring harness and connectors.
connectors for an open or short circuit: No Go to the next step.
• Between keyless control module terminal 3W
and instrument cluster terminal 1W
• Between keyless control module terminal 3X
and instrument cluster terminal 1X
Is there any malfunction?
8 Inspect the following wiring harnesses and Yes Repair or replace the suspected wiring harness and
connectors: connector.
• Between PCM terminal 1BG and instrument No Go to the next step.
cluster terminal 1W
• Between PCM terminal 1BL and instrument
cluster terminal 1X
Is there any malfunction?

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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
9 Verify the following: Yes Go to the next step.
• Vacuum connection No Service if necessary.
• External fuel shut off or accessory (such as Repeat Step 9.
kill switch, alarm)
• Fuel quality: proper octane, contamination,
winter/summer blend
• No air leakage from intake-air system
• Intake-air system restriction (such as air
cleaner element, fresh air duct)
• Proper sealing of intake manifold and
components attached to intake manifold
• Ignition wiring
• Electrical connections
• Fuses
• Smooth operation of throttle valve
Are all items normal?
10 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position • Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs. Communication error message is displayed:
Are there any DTCs displayed? Inspect for the following:
• Open circuit in wiring harness between main
relay and PCM terminal 1BO or 1BJ
• Open main relay GND circuit
• Open or short circuit in wiring harness between
the DLC-2 and PCM terminal 1BL or 1BG
• Main relay is stuck open.
• Open or poor GND circuit (PCM terminal 1D, 1J,
1BP, 1BK)
• Poor connection of vehicle body GND
No No DTC is displayed:
Go to the next step.
11 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access the APP1 and APP2, APP3 PIDs. Crank No Inspect for the following:
the engine with accelerator pedal released. • APP sensor
Are the APP1 and APP2, APP3 PIDs indicating • Wiring harnesses and connectors for following:
that the accelerator pedal is in the released — PCM terminal 1AC—APP sensor terminal B
position? — PCM terminal 1AH—APP sensor terminal C
— PCM terminal 1Y—APP sensor terminal D
— PCM terminal 1AK—APP sensor terminal E
— PCM terminal 1BA—APP sensor terminal F
— PCM terminal 1AD—APP sensor terminal G
— PCM terminal 1AG—APP sensor terminal H
12 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access the TP1, TP2 PID. Crank the engine with No Inspect for the following:
accelerator pedal released. • TP sensor
Are the TP1, TP2 PID indicates the closed • Wiring harnesses and connectors for following:
throttle position? — PCM terminal 2BO—TP sensor terminal A
— PCM terminal 2BR—TP sensor terminal B
— PCM terminal 2AD—TP sensor terminal C
— PCM terminal 2D—TP sensor terminal D
— PCM terminal 2AH—TP sensor terminal E
— PCM terminal 2Z—TP sensor terminal F
13 Does the engine start with the throttle valve Yes Go to Step 29.
closed? No Go to the next step.
14 Will the engine start and run smoothly at part Yes Inspect the electronic throttle control system operation.
throttle? (See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
No Go to the next step.

01-03–22
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
15 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access RPM PID. No Inspect for the following:
Is RPM PID indicating the engine speed when • Open or short circuit in CKP sensor
cranking the engine? • Open or short circuit in wiring harness between
CKP sensor terminal A and PCM terminal 2P
• Open or short circuit in wiring harness between
CKP sensor terminal B and PCM terminal 2T 01-03
• Open or short circuit in CKP sensor wiring
harnesses
If CKP sensor and wiring harness are normal, go to the
next step.
16 Visually inspect the CKP sensor and teeth of Yes Go to the next step.
crankshaft pulley. No Replace the malfunctioning part.
Are CKP sensor and teeth of crankshaft pulley
normal?
17 Inspect the ignition coil related wiring harness Yes Go to the next step.
condition (intermittent open or short circuit) for No Repair the wiring harnesses.
all cylinders. Are wiring harness conditions
normal?
18 Perform the spark test. Yes Go to the next step.
(See 01-03-60 ENGINE CONTROL SYSTEM No Repair or replace the malfunctioning part according to
OPERATION INSPECTION [MZI-3.5].) spark test result.
Is strong blue spark visible at each cylinder?
19 Inspect the spark plug conditions. Yes Spark plug is wet or covered with carbon:
Is spark plug wet, covered with carbon or grayish Inspect for fuel leakage from injector.
white? Spark plug is grayish white:
Inspect the fuel injector for clogging.
No Install the spark plugs on original cylinders.
Go to the next step.
20 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace the PCV valve.
21 visually inspect the exhaust system part. Yes Replace the suspected part.
Is there any deformed exhaust system part? No Go to the next step.
22 Install the fuel pressure gauge between the fuel Yes Go to the next step.
pipe and the fuel distributor. No Zero or low:
Short check connector terminal F/P to body
Inspect the fuel pump relay and fuel pump circuit.
GND using a jumper wiring.
Inspect the fuel line for clogging.
Turn the ignition switch to the ON position.
If there is no malfunction, replace the fuel pump
Is fuel line pressure correct when ignition switch
unit.
is turned on/off five times?
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
(See 01-14-6 FUEL LINE PRESSURE
INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
23 Visually inspect the fuel injector O-ring and fuel Yes Go to the next step.
line for fuel leakage. No Inspect the fuel injector.
Service if necessary. If the fuel injector is normal, replace the fuel pump unit.
Is the fuel line pressure held after the ignition (See 01-14-16 FUEL PUMP UNIT REMOVAL/
switch is turned off? INSTALLATION [MZI-3.5].)
(See 01-14-6 FUEL LINE PRESSURE
INSPECTION [MZI-3.5].)
24 Disconnect the vacuum hose between the purge Yes Inspect if the purge solenoid valve is stuck open
solenoid valve and the intake manifold from mechanically.
purge solenoid valve side. Inspect the evaporative emission control system.
Plug opening end of vacuum hose. No Go to the next step.
Start the engine.
Is starting condition improved?
25 Is air leakage felt or heard at intake-air system Yes Repair or replace the malfunctioning part.
components while racing engine to higher No Go to the next step.
speed?

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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
26 Inspect the variable valve timing control system Yes Go to the next step.
operation. No Repair or replace the malfunctioning part.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
Does variable valve timing control function
properly?
27 Is the engine compression correct? Yes Inspect the valve timing.
No Inspect for causes.
28 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie
NO.7 SLOW RETURN TO IDLE [MZI-3.5]
id0103d1801300

7 SLOW RETURN TO IDLE

DESCRIPTION Engine takes more time than normal to return to idle speed.
• CHT sensor malfunction
• Thermostat is stuck open.
POSSIBLE CAUSE
• Throttle body malfunction
• Air leakage from intake-air system

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
2 Remove thermostat and inspect operation. Yes ECT and thermostat are normal.
(See 01-12-10 THERMOSTAT REMOVAL/ Go to the next step.
INSTALLATION [MZI-3.5].) No Access ECT PID on the M-MDS.
(See 01-12-11 THERMOSTAT INSPECTION Inspect for both ECT PID and temperature gauge on
[MZI-3.5].) instrument cluster readings.
Is thermostat normal? If temperature gauge on instrument cluster indicates
normal range but ECT PID is not same as temperature
gauge reading, inspect CHT sensor.
If temperature gauge on instrument cluster indicates
cold range but ECT PID is normal, inspect temperature
gauge and heat gauge unit.
3 Is throttle body free of contamination? Yes Inspect for air leakage from the intake-air system
components while racing the engine to higher speed.
No Clean or replace throttle body.
4 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–24
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.8 ENGINE RUNS ROUGH/ROLLING IDLE [MZI-3.5]
id0103d1801400

8 ENGINE RUNS ROUGH/ROLLING IDLE

• Engine speed fluctuates between specified idle speed and lower speed and engine shakes
DESCRIPTION excessively.
• Idle speed is too slow and engine shakes excessively.
• Air leakage from intake-air system parts
• A/C system operation is improper 01-03
• Erratic signal to ignition coil
• Spark plug malfunction
• Purge solenoid valve malfunction
• Improper operation of electronic throttle control system
• Idle learning of electronic throttle control system is not completed
• Erratic or no signal from CMP sensor
• Low engine compression
• Improper valve timing
• Improper variable valve timing control system operation
• Erratic signal from CKP sensor
• Improper air / fuel mixture ratio control operation (abnormal signal form MAF sensor or HO2S)
• Open or short circuit in PCM GND circuit
• Poor fuel quality
• PCV valve malfunction
• Air cleaner restriction
• Restriction in exhaust system
• Disconnected electrical connectors
• Inadequate fuel pressure
• Fuel pump body mechanical malfunction
• Improper load signal input
• Fuel line restriction or clogging
POSSIBLE CAUSE • Improper fuel injection control operation
• Fuel leakage from fuel injector
• Fuel injector clogging
• Engine overheating
• Vacuum leakage
• Pressure regulator malfunction (built-in fuel pump unit)

Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair
procedures. Read following warnings before servicing the fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Warm up the engine. Yes Troubleshooting completed. (Cause of this symptom is
Idle the engine for 5 min. that the idle learning of electronic throttle control
Is the symptom disappeared? system is not completed.)
No Go to the next step.

01-03–25
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
2 Verify the following: Yes Go to the next step.
• External fuel shut off or accessory (such as No Service if necessary.
kill switch, alarm) Repeat Step 2.
• Fuel quality (such as proper octane,
contamination, winter/summer blend)
• No air leakage from intake-air system
• Proper sealing of intake manifold and
components attached to intake manifold
• Ignition wiring
• Electrical connections
• Fuses
• Smooth operation of throttle valve
• PCM GND circuit (1D, 1J, 1BP, 1BK)
Are all items normal?
3 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
4 Is the engine overheating? Yes Go to symptom troubleshooting “No.17 Cooling system
concerns - Overheating”.
(See 01-03-42 NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING [MZI-3.5].)
No Go to the next step.
5 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access MAF PID. No Inspect for open or short circuit of MAF sensor and
Drive vehicle with monitoring PID. Is MAF PID related wiring harness.
within specification?
6 Note Yes Go to the next step.
• The following test is for engine running at No If the A/C is always on, go to symptom troubleshooting
rough idle with A/C on. If other symptoms “No.24 A/C is always on or A/C compressor runs
exist, go to the next step. continuously”.
(See 01-03-50 NO.24 A/C IS ALWAYS ON OR A/C
Connect pressure gauge to A/C low and high COMPRESSOR RUNS CONTINUOUSLY [MZI-3.5].)
pressure side lines. For other symptoms, inspect the following:
Start engine and idle it. • Refrigerant charging amount
Turn the A/C switch on. • Condenser fan operation
Measure low side and high side pressures.
Are pressures within specifications?
(See 07-10-6 REFRIGERANT PRESSURE
CHECK.)
7 Note Yes Go to the next step.
• The following test is for engine running No Inspect power steering pressure switch operation and
rough with P/S on. If other symptoms wiring harness between P/S pressure switch and PCM
exist, go to the next step. terminal 2I.

Connect the M-MDS to the DLC-2.

Start the engine and idle it.
Access PSP PID.
Is PSP PID within specification?
8 Visually inspect the CKP sensor and teeth of Yes Go to the next step.
crankshaft pulley. No Replace the malfunctioning part.
Are the CKP sensor and teeth of crankshaft
pulley normal?
9 Inspect the ignition coil related wiring harness Yes Go to the next step.
condition (intermittent open or short circuit) for No Repair the wiring harnesses.
all cylinders. Are wiring harness conditions
normal?
10 Inspect the spark plug condition. Yes Spark plug is wet or covered with carbon:
Is the spark plug wet, covered with carbon or Inspect for fuel leakage from injector.
grayish white? Spark plug is grayish white:
Inspect the fuel injector for clogging.
No Install the spark plugs on original cylinders.
Go to the next step.

01-03–26
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
11 Perform the electronic throttle control system Yes Go to the next step.
operation inspection. No Repair or replace the malfunctioning part according to
(See 01-03-60 ENGINE CONTROL SYSTEM electronic throttle control system operation inspection
OPERATION INSPECTION [MZI-3.5].) results.
Does the electronic throttle control system
function properly?
12 Install fuel pressure gauge between fuel pipe Yes Go to the next step. 01-03
and fuel distributor. No Low:
Start the engine and run it at idle.
Inspect the fuel line for clogging.
Measure fuel line pressure during idle.
If there is no malfunction, replace fuel pump unit.
Is fuel line pressure correct during idle?
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
(See 01-14-6 FUEL LINE PRESSURE
INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
13 Visually inspect for fuel leakage at fuel injector, Yes Go to the next step.
O-ring, and fuel line. No Inspect fuel injector.
Service if necessary. If fuel injector is normal, replace fuel pump unit.
Does fuel line pressure hold after ignition switch (See 01-14-16 FUEL PUMP UNIT REMOVAL/
is turned off? INSTALLATION [MZI-3.5].)
(See 01-14-6 FUEL LINE PRESSURE
INSPECTION [MZI-3.5].)
14 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Start the engine and idle it. No LONG FT1 PID, LONG FT2 PID is out of specification.
Access LONG FT1 PID, LONG FT2 PID. Less than specification (too rich):
Measure LONG FT1 PID, LONG FT2 PID at idle. • Inspect EVAP control system.
Is PID value normal? Greater than specification (too lean):
• Inspect for air leakage at intake-air system
components.
— If system is normal, go to the next step.
15 Disconnect the vacuum hose between the purge Yes Check if purge solenoid valve is stuck open
solenoid valve and the intake manifold from mechanically.
purge solenoid valve side. Inspect EVAP control system.
Plug opening end of vacuum hose. No Go to the next step.
Start the engine.
Does the engine condition improve?
16 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace the PCV valve.
17 Visually inspect the exhaust system part. Yes Replace the suspected part.
Is there any deformed exhaust system part? No Go to the next step.
18 Visually inspect the CMP sensor and teeth of Yes Go to the next step.
camshaft. No Replace the malfunctioning part.
Are the CMP sensor and teeth of camshaft
normal?
19 Inspect variable valve timing control system Yes Go to the next step.
operation. No Repair or replace the malfunctioning part.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
Does variable valve timing control system
function properly?
20 Is engine compression correct? Yes Inspect the valve timing.
No Inspect for causes.
21 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–27
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.9 FAST IDLE/RUNS ON [MZI-3.5]
id0103d1801500

9 FAST IDLE/RUNS ON
• The engine speed continues at fast idle after warm-up.
DESCRIPTION
• The engine runs after the ignition switch is turned off.
• CHT sensor malfunction
• Air leakage from intake-air system
• Throttle body malfunction
POSSIBLE CAUSE • Accelerator pedal position sensor misadjustment
• Cruise control system operation improperly
• Improper load signal input
• Improper operation of electronic throttle control system

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access ECT PID. No ECT PID is higher than 112°C {234°F}:
Start and warm up engine to normal operating
Go to symptom troubleshooting “No.17 Cooling
temperature.
system concerns - Overheating”.
Is ECT PID between 82—112°C {180—234°F}?
ECT PID is less than 82°C {180°F}:
Go to symptom troubleshooting “No.18 Cooling
system concerns - Runs cold”.
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
3 Access and monitor PSP and TR PIDs. Yes Go to the next step.
Are PIDs values normal? No If the AC_REQ PID is not normal:
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
• Inspect A/C switch, refrigerant pressure switch, and
fan switch, and related wiring harness for vibration
or intermittent open/short circuit.
If the TR PID is not normal:
• Inspect TR switch and related wiring harness for
vibration or intermittent open/short circuit.
If the PSP PID is not normal:
• Inspect power steering switch and related wiring
harness for vibration or intermittent open/short
circuit.
4 Is there air leakage felt or heard at intake-air Yes Repair or replace parts if necessary.
system components while racing engine to No Inspect the following:
higher speed? • Electronic throttle control system operation
• Accelerator pedal position sensor
5 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–28
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.10 LOW IDLE/STALLS DURING DECELERATION [MZI-3.5]
id0103d1801600

10 LOW IDLE/STALLS DURING DECELERATION

DESCRIPTION • Engine stops unexpectedly at the beginning of deceleration or recovery from deceleration.
• Vacuum leakage
• Improper operation of electronic throttle control system
• Air leakage from intake-air system
• Improper air/fuel mixture ratio control 01-03
• Evaporative emission control system malfunction
• Accelerator pedal position sensor or related circuit malfunction
POSSIBLE CAUSE
• Accelerator pedal position sensor misadjustment
• TP sensor or related circuit malfunction
• MAF sensor or related circuit malfunction
• Brake switch or related circuit malfunction
• TR switch or related circuit malfunction
• Improper A/C magnetic clutch operation

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Does the engine idle roughly? Yes Go to symptom troubleshooting "No.8 Engine runs
rough/rolling idle".
(See 01-03-25 NO.8 ENGINE RUNS ROUGH/
ROLLING IDLE [MZI-3.5].)
No Go to the next step.
2 Turn off the A/C switch and fan switch. Yes Go to symptom troubleshooting “No.24 A/C is always
Does the A/C magnetic clutch engage? on or A/C compressor runs continuously.“
(See 01-03-50 NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY [MZI-3.5].)
No Go to the next step.
3 Verify the following: Yes Go to the next step.
• Proper routing of and no damage to vacuum No Service if necessary.
lines Repeat Step 3.
• No air leakage from intake-air system
Are all items normal?
4 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
5 Perform the electronic throttle control system Yes Go to the next step.
operation inspection. No Repair or replace the malfunctioning part according to
(See 01-03-60 ENGINE CONTROL SYSTEM electronic throttle control system operation inspection
OPERATION INSPECTION [MZI-3.5].) results.
Does the electronic throttle control system
function properly?
6 Disconnect the vacuum hose between the purge Yes Inspect the evaporative emission control system.
solenoid valve and the intake manifold from No Go to the next step.
purge solenoid valve side.
Plug opening end of vacuum hose.
Drive the vehicle.
Does the engine condition improve?
7 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access APP1, APP2, APP3, TP1, TP2, MAF No APP1, APP2, APP3 PIDs:
and VSS PIDs.
Inspect the accelerator pedal position sensor.
Monitor each PID while driving vehicle.
(See 01-40-5 PCM INSPECTION [MZI-3.5].) TP1, TP2 PID:
Are PIDs normal? Inspect TP sensor.
MAF PID:
Inspect MAF sensor.
VSS PID:
Inspect VSS.

01-03–29
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
8 Access and monitor BOO, TR PIDs. Yes Go to the next step.
Are PIDs values normal? No If the BOO PID is not normal:
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
• Inspect brake switch, and related wiring harness for
vibration or intermittent open/short circuit.
If the TR PID is not normal:
• Inspect TR switch and related wiring harness for
vibration or intermittent open/short circuit.
9 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE,
SURGES [MZI-3.5]
id0103d1801700

ENGINE STALLS/QUITS—ACCELERATION/CRUISE
ENGINE RUNS ROUGH—ACCELERATION/CRUISE
MISSES—ACCELERATION/CRUISE
11
BUCK/JERK—ACCELERATION/CRUISE/DECELERATION
HESITATION/STUMBLE—ACCELERATION
SURGES—ACCELERATION/CRUISE
• Engine stops unexpectedly at the beginning of acceleration or during acceleration.
• Engine stops unexpectedly while cruising.
• Engine speed fluctuates during acceleration or cruising.
DESCRIPTION • Engine misses during acceleration or cruising.
• Vehicle bucks/jerks during acceleration, cruising, or deceleration.
• Momentary pause at beginning of acceleration or during acceleration
• Momentary minor irregularity in engine output

01-03–30
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

ENGINE STALLS/QUITS—ACCELERATION/CRUISE
ENGINE RUNS ROUGH—ACCELERATION/CRUISE
MISSES—ACCELERATION/CRUISE
11
BUCK/JERK—ACCELERATION/CRUISE/DECELERATION
HESITATION/STUMBLE—ACCELERATION
SURGES—ACCELERATION/CRUISE
• Improper A/C system operation
• Erratic signal or no signal from CMP sensor
• Air leakage from intake-air system parts
01-03
• Purge solenoid valve malfunction
• Improper operation of electronic throttle control system
• Erratic signal from CKP sensor
• Low engine compression
• Vacuum leakage
• Poor fuel quality
• Main relay intermittent malfunction
• Throttle body malfunction
• Engine overheating
• Spark plug malfunction
• Improper air/fuel mixture ratio control operation
• Erratic signal to ignition coil
• Air cleaner restriction
• PCV valve malfunction
• Fuel flow into evaporative purge hose
• Improper valve timing due to jumping out timing chain
• Restriction in exhaust system
• Intermittent open or short circuit in fuel body pump circuit
• Inadequate fuel pressure
• Fuel pump mechanical malfunction
• Check valve (two-way) malfunction integrated with fuel tank
• Fuel leakage from fuel injector
POSSIBLE CAUSE • Fuel injector clogging
• Fuel line restriction or clogging
• Pressure regulator malfunction (built-in fuel pump unit)
• Erratic signal form APP sensor
• Erratic signal form TP sensor
• Intermittent open or short circuit of MAF sensor, TP sensor, APP sensor and VSS
• ATX malfunction
• Loose attaching bolts or worn engine mounts

Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

01-03–31
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Verify the following: Yes Go to the next step.
• Vacuum connection No Service if necessary.
• Air cleaner element Repeat Step 1.
• No air leakage from intake-air system
• No restriction of intake-air system
• Proper sealing of intake manifold and
components attached to intake manifold
• Ignition wiring
• Fuel quality (such as proper octane,
contamination, winter/summer blend)
• Electrical connections
• Smooth operation of throttle valve
Are all items normal?
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
3 Is engine overheating? Yes Go to symptom troubleshooting “No.17 Cooling system
concerns - Overheating”.
No Go to the next step.
4 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access APP1, APP2, APP3, RPM, VPWR, MAF, No APP1, APP2, APP3 PIDs:
TP1, TP2 and VSS PIDs.
Inspect if output signal from APP sensor changes
Drive the vehicle with monitoring PIDs.
smoothly.
Are PIDs within specifications?
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
RPM PID:
Inspect the CKP sensor and related wiring harness for
vibration or intermittent open/short circuit.
VPWR PID:
Inspect for open circuit intermittently.
MAF PID:
Inspect for open circuit of the MAF sensor and related
wiring harness intermittently.
TP1, TP2 PID:
Inspect if output signal from TP sensor changes
smoothly.
VSS PID:
Inspect for open circuit of VSS and related wiring
harness intermittently.
5 Visually inspect the CKP sensor and teeth of Yes Go to the next step.
crankshaft pulley. No Replace the malfunctioning part.
Are CKP sensor and teeth of crankshaft pulley
normal?
6 Inspect the spark plug conditions. Yes Spark plug is wet or covered with carbon:
Is spark plug wet, covered with carbon or grayish Inspect for fuel leakage from fuel injector.
white? Spark plug is grayish white:
Inspect the fuel injector for clogging.
No Install the spark plugs on original cylinders.
Go to the next step.
7 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace the PCV valve.
8 Perform the electronic throttle control system Yes Go to the next step.
operation inspection. No Repair or replace the malfunctioning part according to
(See 01-03-60 ENGINE CONTROL SYSTEM electronic throttle system operation inspection results.
OPERATION INSPECTION [MZI-3.5].)
Does the electronic throttle control system
function properly?
9 Visually inspect deformed exhaust system part. Yes Replace the suspected part.
Is there any deformed exhaust system part? No Go to the next step.

01-03–32
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
10 Install fuel pressure gauge between the fuel pipe Yes Go to the next step.
and fuel distributor. No Zero or low:
Short check connector terminal F/P to body
Inspect the fuel pump relay and fuel pump circuit.
GND using a jumper wiring.
Inspect the fuel line for clogging.
Turn the ignition switch to the ON position.
If there is no malfunction, replace the fuel pump
Is fuel line pressure correct with ignition switch to
unit.
ON position?
(See 01-14-6 FUEL LINE PRESSURE
(See 01-14-16 FUEL PUMP UNIT REMOVAL/ 01-03
INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
11 Visually inspect for fuel leakage at fuel injector Yes Go to the next step.
O-ring and fuel line. No Inspect the fuel injector.
Service if necessary. If the fuel injector is normal, replace the fuel pump unit.
Is fuel line pressure held after ignition switch is (See 01-14-16 FUEL PUMP UNIT REMOVAL/
turned off? INSTALLATION [MZI-3.5].)
(See 01-14-6 FUEL LINE PRESSURE
INSPECTION [MZI-3.5].)
12 Note Yes Go to the next step.
• The following test is for engine stall with No If the A/C is always on, go to symptom troubleshooting
the A/C on. If other symptom exists, go to “No.24 A/C is always on or A/C compressor runs
the next step. continuously”.
(See 01-03-50 NO.24 A/C IS ALWAYS ON OR A/C
Connect a pressure gauge to A/C low and high COMPRESSOR RUNS CONTINUOUSLY [MZI-3.5].)
pressure side lines. For other symptoms, inspect the following:
Turn the A/C on and measure low side and high • Refrigerant charging amount
side pressure. • Condenser fan operation
Are pressures within specifications?
(See 07-10-6 REFRIGERANT PRESSURE
CHECK.)
13 Note Yes Go to the next step.
• The following test should be performed for No Repair or replace the malfunctioning part.
symptom with cruise control ON. If other
symptoms exist, go to the next step.

Inspect cruise control system.

Is cruise control system normal?
14 Inspect the front HO2S. Yes Go to the next step.
(See 01-40-21 FRONT HEATED OXYGEN No Replace the front HO2S.
SENSOR (HO2S) INSPECTION [MZI-3.5].) (See 01-40-23 REAR HEATED OXYGEN SENSOR
Is the front HO2S normal? (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
15 Inspect the evaporative purge hose between the Yes Inspect the check valve (two-way).
fuel tank and the purge valve. (See 01-14-14 FUEL TANK INSPECTION [MZI-3.5].)
Does fuel flow into evaporative purge hose? No Go to the next step.
16 Disconnect the vacuum hose between the purge Yes Go to the next step.
solenoid valve and the intake manifold from the Inspect if the purge solenoid valve is stuck open
purge solenoid valve side. mechanically.
Plug opening end of vacuum hose. Inspect the evaporative emission control system.
Drive the vehicle. No Go to the next step.
Does the engine condition improve?
17 Visually inspect the CMP sensor and projections Yes Go to the next step.
of camshaft pulley. No Replace the malfunctioning part.
Are CMP sensor and projections of camshaft
pulley normal?
18 Is the engine compression correct? Yes Inspect the following:
• Valve timing
• Internal transaxle part
• Engine mounts
• Check valve (two-way)
No Inspect for cause.

01-03–33
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
19 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie
NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE [MZI-3.5]
id0103d1804800

12 LACK/LOSS OF POWER—ACCELERATION/CRUISE
DESCRIPTION Performance is poor under load (such as power down when climbing hills).
• Improper A/C system operation
• Erratic signal or no signal from CMP sensor
• Air leakage from intake-air system parts
• Restriction in intake-air system
• Intake air temperature too hot
• Improper operation of electronic throttle control system
• Purge control solenoid malfunction
• Brake dragging
• Erratic signal from CKP sensor
• Low engine compression
• Vacuum leakage
• Poor fuel quality
• Erratic signal to ignition coil
• Engine overheating
• Throttle body malfunction
• Spark plug malfunction
• PCV valve malfunction
• Improper valve timing due to jumping out of timing chain
• Improper variable valve timing control operation
• Restriction in exhaust system
• Intermittent open or short in fuel pump related circuit
• Inadequate fuel pressure
• Fuel pump mechanical malfunction
• Fuel line restriction or clogging
POSSIBLE CAUSE • Fuel leakage from fuel injector
• Fuel injector clogging
• Erratic signal from accelerator pedal position sensor
• Erratic signal from TP sensor
• Intermittent open or short circuit in MAF sensor, Accelerator pedal position sensor, TP sensor, IAT
sensor and VSS
• ATX malfunction

Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

01-03–34
1890-1U-06H(01-03).fm 35 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Verify the following: Yes Go to the next step.
• Vacuum connection No Service if necessary.
• Restriction in intake-air system (such as air Repeat Step 1.
cleaner element, fresh air duct)
• No air leakage from intake-air system
• No restriction of intake-air system
• Proper sealing of intake manifold and
01-03
components attached to intake manifold
• Fuel quality (such as proper octane,
contamination, winter/summer blend)
Are all items normal?
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
No No DTC is displayed:
Are there any DTCs displayed?
Go to the next step.
3 Is the engine overheating? Yes Go to symptom troubleshooting “No.17 Cooling system
concerns-Overheating”.
No Go to the next step.
4 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access APP1, APP2, APP3, RPM, MAF, TP1, No APP1, APP2, APP3 PIDs:
TP2, IAT and VSS PIDs.
Inspect if output signal accelerator pedal position
Drive vehicle while monitoring PIDs.
sensor changes smoothly.
Are PIDs within specifications?
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
RPM PID:
Inspect CKP sensor and related wiring harness for
vibration or intermittent open/short circuit or both.
MAF PID:
Inspect for intermittent open circuit of MAF sensor and
related wiring harness.
TP1, TP2 PID:
Inspect if output signal TP sensor changes smoothly.
IAT PID:
Inspect for air suction in intake-air system.
If normal, inspect intermittent short circuit of IAT
sensor and related wiring harnesses.
VSS PID:
Inspect for intermittent open circuit of VSS and related
wiring harness.
5 Visually inspect the CKP sensor and teeth of Yes Go to the next step.
crankshaft pulley. No Replace the malfunctioning part.
Are the CKP sensor and teeth of crankshaft
pulley normal?
6 Inspect the spark plug condition. Yes Spark plug is wet or covered with carbon:
Is spark plug wet, covered with carbon or grayish Inspect the fuel injector for fuel leakage.
white? Inspect spark plug and high-tension lead.
Spark plug is grayish white:
Inspect the fuel injector for clogging.
No Install the spark plugs on original cylinders.
Go to the next step.
7 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace PCV valve.
8 Perform electronic throttle control system Yes Go to the next step.
operation inspection. No Repair or replace the malfunctioning part according to
(See 01-03-60 ENGINE CONTROL SYSTEM electronic throttle control system operation inspection
OPERATION INSPECTION [MZI-3.5].) results.
Does electronic throttle control system function
properly?
9 visually inspect deformed exhaust system part. Yes Replace the suspected part.
Is there any deformed exhaust system part? No Go to the next step.

01-03–35
1890-1U-06H(01-03).fm 36 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
10 Install the fuel pressure gauge between the fuel Yes Go to the next step.
pipe and the fuel distributor. No Zero or low:
Short check connector terminal F/P to body
Inspect the fuel pump relay and fuel pump circuit.
GND using a jumper wiring.
Inspect the fuel line for clogging.
Turn the ignition switch to the ON position.
If there is no malfunction, replace the fuel pump
Is fuel line pressure correct with ignition switch to
unit.
ON position?
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
(See 01-14-6 FUEL LINE PRESSURE
INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
11 Note Yes Go to the next step.
• The following test is for engine stalling No If A/C is always on, go to symptom troubleshooting
with the A/C on concern. If other “No.24 A/C is always on or A/C compressor runs
symptoms exist, go to the next step. continuously”.
(See 01-03-50 NO.24 A/C IS ALWAYS ON OR A/C
Connect pressure gauge to the A/C low and high COMPRESSOR RUNS CONTINUOUSLY [MZI-3.5].)
side pressure lines. For other symptoms, inspect the following:
Turn the A/C on and measure low side and high • Refrigerant charging amount
side pressures. • Condenser fan operation
Are pressures within specifications?
(See 07-10-6 REFRIGERANT PRESSURE
CHECK.)
12 Inspect for A/C cut-off operation. Yes Go to the next step.
(See 01-03-60 ENGINE CONTROL SYSTEM No Inspect A/C cut-off system components.
OPERATION INSPECTION [MZI-3.5].)
Does the A/C cut-off function properly?
13 Disconnect the vacuum hose between the purge Yes Inspect if purge solenoid valve is stuck open
solenoid valve and the intake manifold from mechanically.
purge solenoid valve side. Inspect the evaporative emission control system.
Plug opening end of vacuum hose. (See 01-03-60 ENGINE CONTROL SYSTEM
Drive the vehicle. OPERATION INSPECTION [MZI-3.5].)
Does the engine condition improve? No Go to the next step.
14 Visually inspect the CMP sensor and projections Yes Go to the next step.
of camshaft pulley. No Replace the malfunctioning part.
Are the CMP sensor and projections of camshaft
pulley normal?
15 Inspect the variable valve timing control system Yes Go to the next step.
operation. No Repair or replace the malfunctioning part according to
(See 01-03-60 ENGINE CONTROL SYSTEM variable valve timing control system inspection results.
OPERATION INSPECTION [MZI-3.5].)
Does the variable valve timing control system
function properly?
16 Is the engine compression correct? Yes Inspect the following:
• Valve timing
• Internal transaxle components
• Brake system for dragging
No Inspect for cause.
17 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–36
1890-1U-06H(01-03).fm 37 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE [MZI-3.5]
id0103d1812100

13 KNOCKING/PINGING - ACCELERATION/CRUISE
Sound is heard when air/fuel mixture is ignited by something other than spark plug (such as hot spot in
DESCRIPTION
combustion chamber).
• Engine overheating due to cooling system malfunction
• CHT sensor malfunction
• IAT sensor malfunction 01-03
• MAF sensor malfunction
• Knock sensor malfunction
• Erratic signal from CMP sensor
• Inadequate engine compression
• Inadequate fuel pressure

Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
POSSIBLE CAUSE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access ECT PID. No Inspect the cooling system for cause of overheating.
Verify ECT PID is less than 116°C {241°F}
during driving.
Is ECT PID less than specification?
2 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access IAT and MAF PIDs. No IAT PID:
Monitor each PID.
Inspect IAT sensor
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
Are PIDs normal? MAF PID:
Inspect MAF sensor
3 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
4 Is engine compression correct? Yes Go to the next step.
No Inspect for cause.
5 Install fuel pressure gauge between fuel pipe Yes Inspect the ignition timing.
and fuel distributor. No Low:
Start the engine and idle it.
Inspect the fuel pump relay and fuel pump circuit.
Measure fuel line pressure during idle.
Inspect the fuel line for clogging.
Is fuel line pressure correct during idle?
If there is no malfunction, replace the fuel pump
(See 01-14-6 FUEL LINE PRESSURE
unit.
INSPECTION [MZI-3.5].)
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
6 Inspect the knock sensor. Yes Inspect ignition timing.
Is the knock sensor normal? No Replace the knock sensor.

01-03–37
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
7 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie
NO.14 POOR FUEL ECONOMY [MZI-3.5]
id0103d1802000

14 POOR FUEL ECONOMY

DESCRIPTION Fuel economy is unsatisfactory.
• Contaminated air cleaner element
• Engine cooling system malfunction
• Improper ATF level
• Weak spark
• Poor fuel quality
• Erratic or no signal from CMP sensor
• Improper variable valve timing control system operation
• Improper coolant level
• Inadequate fuel pressure
• Spark plug malfunction
• PCV valve malfunction
• Brake dragging
• Improper valve timing due to jumping out of timing chain
• Contaminated MAF sensor
• Improper engine compression
• Exhaust system clogging
POSSIBLE CAUSE
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair
procedures. Read following warnings before servicing fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

01-03–38
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Inspect for the following: Yes Go to the next step.
• Air cleaner element for contamination No Service if necessary.
• ATF level Repeat Step 1.
• Fuel quality
• Coolant level
• Brake dragging
Are all items normal?
01-03
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
3 Access ECT PID. Yes Go to the next step.
Drive vehicle while monitoring PID. No Inspect for coolant leakage, cooling fan and condenser
(See 01-40-5 PCM INSPECTION [MZI-3.5].) fan operations or thermostat operation.
Is PID within specification?
4 Perform the spark test. Yes Go to the next step.
(See 01-03-60 ENGINE CONTROL SYSTEM No Repair or replace the malfunctioning part according to
OPERATION INSPECTION [MZI-3.5].) spark test result.
Is strong blue spark visible at each cylinder?
5 Install the fuel pressure gauge between the fuel Yes Go to the next step.
pipe and the fuel distributor. No Low:
Start the engine and idle it.
Inspect the fuel pump relay and fuel pump circuit.
Measure fuel line pressure during idle.
Inspect the fuel line for clogging.
Is fuel line pressure correct during idle?
If there is no malfunction, replace the fuel pump
(See 01-14-6 FUEL LINE PRESSURE
unit
INSPECTION [MZI-3.5].)
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
6 Inspect for variable valve timing control system Yes Go to the next step.
operation. No Repair or replace the malfunctioning part.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
Does the variable valve timing control system
function properly?
7 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace the PCV valve.
8 Visually inspect the exhaust system part. Yes Replace the suspected part.
Is there any deformed exhaust system? No Go to the next step.
9 Inspect for contaminated MAF sensor. Yes Go to the next step.
Is there any contamination? No Inspect for cause.
10 Inspect the MAF sensor for contamination. Yes Replace MAF sensor.
Is there any contamination? No Go to the next step.
11 Is engine compression correct? Yes Inspect the valve timing.
No Inspect for cause.
12 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–39
1890-1U-06H(01-03).fm 40 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.15 EMISSION COMPLIANCE [MZI-3.5]
id0103d1802100

15 EMISSION COMPLIANCE
DESCRIPTION Fails emissions test.
• Vacuum lines leakage or blockage
• Cooling system malfunction
• Spark plug malfunction
• Leakage from intake manifold
• Erratic or no signal from CMP sensor
• Inadequate fuel pressure
• PCV valve malfunction or incorrect valve installation
• Exhaust system clogging
• Fuel tank ventilation system malfunction
• Fuel-filler cap malfunction
• Charcoal canister damage
• Air cleaner element clogging or restriction
• Throttle body malfunction
• Erratic signal to ignition coil
• Improper air/fuel mixture ratio control operation
• Bend or open circuit HO2S wiring harness
• Catalyst converter malfunction
• Engine internal parts malfunction
• Excessive carbon is built up in combustion chamber
POSSIBLE CAUSE • Improper engine compression
• Improper valve timing

Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair
procedures. Read following warnings before servicing fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Inspect for the following: Yes Go to the next step.
• Vacuum lines for leakage or blockage No Service if necessary.
• Electrical connections Repeat Step 1.
• Proper maintenance schedule followed
• Intake-air system and air cleaner element
concerns: obstructions, leakage or dirtiness
Are all items normal?
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
No No DTC is displayed:
Are there any DTCs displayed?
Go to the next step.
3 Is any other driveability concern present? Yes Go to appropriate symptom troubleshooting.
No Go to the next step.
4 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access ECT PID. No Inspect for coolant leakage, cooling fan and condenser
Warm up the engine and idle it. fan operation or thermostat operation.
Verify ECT PID is correct.
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
Is ECT PID correct?

01-03–40
1890-1U-06H(01-03).fm 41 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
5 Inspect fuel-filler cap. Yes Replace the fuel-filler cap.
(See 01-16-7 FUEL-FILLER CAP INSPECTION No Go to the next step.
[MZI-3.5].)
Is there any leakage at fuel-filler cap?
6 Inspect the front HO2S. Yes Go to the next step.
(See 01-40-21 FRONT HEATED OXYGEN No Replace the front HO2S.
SENSOR (HO2S) INSPECTION [MZI-3.5].) (See 01-40-20 FRONT HEATED OXYGEN SENSOR 01-03
Is front HO2S normal? (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
7 Perform spark test. Yes Go to the next step.
(See 01-03-60 ENGINE CONTROL SYSTEM No Repair or replace the malfunctioning part according to
OPERATION INSPECTION [MZI-3.5].) spark test result.
Is strong blue spark visible at each cylinder?
8 Install the fuel pressure gauge between the fuel Yes Go to the next step.
pipe and the fuel distributor. No Low:
Start the engine and idle it.
Inspect the fuel line for clogging.
Measure fuel line pressure during idle.
If there is no malfunction, replace the fuel pump
Is fuel line pressure correct during idle?
unit.
(See 01-14-6 FUEL LINE PRESSURE
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSPECTION [MZI-3.5].)
INSTALLATION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
9 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace the PCV valve.
10 Inspect for fuel saturation inside charcoal Yes Replace the charcoal canister.
canister. No Inspect the fuel tank vent system.
Is excess amount of liquid fuel present in Then, go to the next step.
canister? (See 01-14-14 FUEL TANK INSPECTION [MZI-3.5].)
11 visually inspect the exhaust system part. Yes Replace the part.
Is there any deformed exhaust system part? No Go to the next step.
12 Inspect the three-way catalytic converter. Yes Go to the next step.
(See 01-15-1 EXHAUST SYSTEM No Replace the three-way catalytic converter.
INSPECTION [MZI-3.5].)
Is the three-way catalytic converter normal?
13 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–41
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.16 HIGH OIL CONSUMPTION/LEAKAGE [MZI-3.5]
id0103d1802200

16 HIGH OIL CONSUMPTION/LEAKAGE

DESCRIPTION Oil consumption is excessive.
• PCV valve malfunction
• Improper dipstick
POSSIBLE CAUSE
• Improper engine oil viscosity
• Engine internal parts malfunction

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace the PCV valve.
2 Inspect for the following: Yes Inspect the internal engine parts such as valves, valve
• External leakage guides, valve stem seals, cylinder head drain passage,
• Proper dipstick and piston rings.
• Proper engine oil viscosity No Service if necessary.
Are all items normal? Repeat Step 2.
3 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie
NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [MZI-3.5]
id0103d1802300

17 COOLING SYSTEM CONCERNS-OVERHEATING

DESCRIPTION Engine runs at higher than normal temperature/overheats.
• Improper coolant level
• Blown fuses
• Coolant leakage
• Excessive A/C system pressure
• A/C system operation is improper
• Improper water/anti-freeze mixture
• Fans reverse rotation
POSSIBLE CAUSE • Poor radiator condition
• Thermostat malfunction
• Radiator hoses damage
• Improper or damaged radiator cap
• Cooling fan is inoperative.
• Coolant overflow system malfunction
• Improper tension of drive belt
• Drive belt damage

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Inspect the following: Yes Go to the next step.
• Engine coolant level No Service if necessary.
• Coolant leakage Repeat Step 1.
• Water and anti-freeze mixture
• Radiator condition
• Collapsed or restricted radiator hoses
• Radiator pressure cap
• Overflow system
• Fan rotational direction
• Fuses
Are all items normal?
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs. No No DTC is displayed:
Are there any DTCs displayed? Go to the next step.

01-03–42
1890-1U-06H(01-03).fm 43 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
3 Start the engine and idle it. Yes Go to Step 5.
Turn the A/C switch on and set blower fan to any No Inspect for the following and repair or replace if
speed. necessary:
Does the A/C compressor engage? • Refrigerant charging amount
• Open circuit in wiring harness between A/C relay
and PCM terminal 1N
• Seized A/C magnetic clutch 01-03
• A/C magnetic clutch malfunction
If all items are normal, go to the next step.
4 Connect the M-MDS to the DLC-2. Yes Go to the next step.
Access AC_REQ PID. No Inspect the following:
Start the engine and idle it. • Refrigerant pressure switch operation
Turn the A/C switch and fan switch on. • The A/C switch is stuck open.
Does AC_REQ PID read on? • Open or short circuit between refrigerant pressure
switch and PCM terminal 1R
• Open circuit of blower motor fan switch and resistor
(if blower motor does not operate)
• The evaporator temperature sensor and A/C
amplifier
5 Inspect cooling fan control system operation. Yes Go to the next step.
(See 01-03-60 ENGINE CONTROL SYSTEM No Repair or replace the malfunctioning part.
OPERATION INSPECTION [MZI-3.5].)
Does the cooling fan control system function
properly?
6 Is the drive belt normal? Yes Go to the next step.
No Replace the drive belt.
7 Is there leakage around the heater unit in Yes Inspect and service heater for leakage.
passenger compartment? No Go to the next step.
8 Is there leakage at the coolant hoses and/or Yes Replace the malfunctioning part.
radiator? No Go to the next step.
9 Cool down the engine. Yes The engine coolant temperature and thermostat are
Remove thermostat and inspect operation. normal, inspect engine block for leakage or blockage.
(See 01-12-10 THERMOSTAT REMOVAL/ No Access ECT PID.
INSTALLATION [MZI-3.5].) Inspect for both ECT PID and temperature gauge
(See 01-12-11 THERMOSTAT INSPECTION readings.
[MZI-3.5].) If temperature gauge on instrument cluster indicates
Is thermostat normal? normal range but ECT PID is not same as temperature
gauge reading, inspect CHT sensor.
If temperature gauge on instrument cluster indicates
overheating but ECT PID is normal, inspect
temperature gauge and heat gauge unit.
10 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–43
1890-1U-06H(01-03).fm 44 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [MZI-3.5]
id0103d1802400

18 COOLING SYSTEM CONCERNS-RUNS COLD

DESCRIPTION Engine takes excessive time to reach normal operating temperature.
• Thermostat malfunction
POSSIBLE CAUSE
• Cooling fan system malfunction

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Is customer complaint “Lack of passenger Yes Inspect A/C and heater system.
compartment heat” only? No Go to the next step.
2 Does the engine speed continue at fast idle? Yes Go to symptom troubleshooting “No.9 Fast idle/runs
on”.
(See 01-03-28 NO.9 FAST IDLE/RUNS ON [MZI-3.5].)
No Go to the next step.
3 Remove the thermostat and inspect operation. Yes Go to the next step.
(See 01-12-10 THERMOSTAT REMOVAL/ No Replace the thermostat.
INSTALLATION [MZI-3.5].)
(See 01-12-11 THERMOSTAT INSPECTION
[MZI-3.5].)
Is thermostat normal?
4 Inspect cooling fan control system operation. Yes Access ECT PID.
(See 01-03-60 ENGINE CONTROL SYSTEM Inspect for both ECT PID and temperature gauge on
OPERATION INSPECTION [MZI-3.5].) instrument cluster readings.
Does the cooling fan control system function If the temperature gauge on the instrument cluster
properly? indicates normal range but ECT PID is not the same as
temperature gauge reading, inspect the CHT sensor.
If the temperature gauge on the instrument cluster
indicates cold range but ECT PID is normal, inspect the
temperature gauge and heat gauge unit.
No Repair or replace the malfunctioning part.
5 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–44
1890-1U-06H(01-03).fm 45 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.19 EXHAUST SMOKE [MZI-3.5]
id0103d1803900

19 EXHAUST SMOKE
DESCRIPTION Blue, black, or white smoke from exhaust system
Blue smoke (Burning oil):
• PCV valve malfunction
• Engine internal oil leakage
White smoke (Water in combustion): 01-03
• Cooling system malfunction (coolant loss)
• Engine internal coolant leakage
Black smoke (Rich fuel mixture):
• Air cleaner restriction
• Intake-air system is collapsed or restricted.
• Fuel return line is restricted.
• Excessive fuel pressure
• Improper engine compression
• Injector fuel leakage
• Ignition system malfunction

POSSIBLE CAUSE Warning

The following troubleshooting flow chart contains fuel system diagnosis and repair
procedures. Read following warnings before servicing fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 What color is smoke coming from the exhaust Blue Burning oil is indicated.
system? Go to the next step.
White Water in combustion is indicated.
Go to Step 3.
Black Rich fuel mixture is indicated.
Go to Step 4.
2 Remove and shake the PCV valve. Yes Inspect for the following:
Does the PCV valve rattle? • Damaged valve guide, stems or valve seals
• Blocked oil drain passage in cylinder head
• Piston ring is not seated, seized or worn.
• Damaged cylinder bore
If other driveability symptoms are present, return to
diagnostic index to service any additional symptoms.
No Replace the PCV valve.
3 Does the cooling system hold pressure? Yes Inspect for the following:
• Cylinder head gasket leakage
• Intake manifold gasket leakage
• Cracked or porous engine block
If other driveability symptoms are present, return to
diagnostic index to service any additional symptoms.
No Inspect for cause.
4 Inspect for the following: Yes Go to the next step.
• Air cleaner restriction No Service if necessary.
• Collapsed or restricted intake-air system Repeat Step 4.
• Restricted fuel return line
Are all items normal?

01-03–45
1890-1U-06H(01-03).fm 46 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
5 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
6 Install the fuel pressure gauge between the fuel Yes Go to the next step.
pipe and the fuel distributor. No Low:
Start the engine and idle it.
Inspect the fuel line for clogging.
Measure fuel line pressure during idle.
If there is no malfunction, replace the fuel pump
Is fuel line pressure correct during idle?
unit.
(See 01-14-6 FUEL LINE PRESSURE
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSPECTION [MZI-3.5].)
INSTALLATION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
7 Perform the spark test. Yes Inspect the CMP sensor.
(See 01-03-60 ENGINE CONTROL SYSTEM (See 01-40-18 CAMSHAFT POSITION (CMP)
OPERATION INSPECTION [MZI-3.5].) SENSOR INSPECTION [MZI-3.5].)
Is strong blue spark visible at each cylinder? No Repair or replace the malfunctioning part according to
spark test result.
8 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–46
1890-1U-06H(01-03).fm 47 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [MZI-3.5]
id0103d1802600

20 FUEL ODOR (IN ENGINE COMPARTMENT)

DESCRIPTION Gasoline fuel smell or visible leakage
• Excessive fuel pressure
• Purge solenoid valve malfunction
• Fuel tank vent system blockage
• Charcoal canister malfunction 01-03
• Fuel leakage from fuel system

Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair
procedures. Read following warnings before servicing fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
POSSIBLE CAUSE
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Visually inspect for fuel leakage at fuel injector Yes Go to the next step.
O-ring and fuel line. No Replace the fuel pump unit.
Service if necessary. (See 01-14-16 FUEL PUMP UNIT REMOVAL/
Install the fuel pressure gauge between the fuel INSTALLATION [MZI-3.5].)
pipe and the fuel distributor.
Start engine and idle it.
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
(See 01-14-6 FUEL LINE PRESSURE
INSPECTION [MZI-3.5].)
2 Inspect for blockage/restriction or open circuit in Yes Replace vacuum hose.
wiring harness between the engine vacuum port No Go to the next step.
and the charcoal canister.
Inspect for blockage in fuel tank vent system.
Is malfunction indicated?
3 Inspect the purge solenoid valve. Yes Go to the next step.
(See 01-16-8 PURGE SOLENOID VALVE No Replace the purge solenoid valve.
INSPECTION [MZI-3.5].) (See 01-16-8 PURGE SOLENOID VALVE REMOVAL/
Is the solenoid operating properly? INSTALLATION [MZI-3.5].)
4 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Inspect charcoal canister for fuel saturation.
If excess amount of liquid fuel is present, replace
the charcoal canister.
5 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–47
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.21 ENGINE NOISE [MZI-3.5]
id0103d1802700

21 ENGINE NOISE
DESCRIPTION Engine noise from under hood
Squeal, click or chirp noise:
• Improper engine oil level
• Improper drive belt tension
• Generator installation (alignment)
• Splash shield or under cover looseness (splashed water to drive belts)
Rattle sound noise:
• Loose parts
Hiss sound noise:
• Vacuum leakage
• Loose spark plug
POSSIBLE CAUSE • Air leakage from intake-air system
Rumble or grind noise:
• Improper drive belt tension
• Improper P/S fluid level
Rap or roar noise:
• Dynamic dumper looseness
• Exhaust system looseness
• Intake-air system looseness
Other noise:
• Camshaft friction gear noise or MLA noise
• Timing chain noise

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Is a squealing, click or chirping sound present? Yes Inspect for the followings:
• Engine oil level
• Drive belt tension
• Splash shield or under cover looseness
• Generator installation (alignment)
No Go to the next step.
2 Is a rumbling or grinding noise present? Yes Inspect for the followings:
• Drive belt tension
• P/S fluid level
No Go to the next step.
3 Is a rattling noise present? Yes Inspect rattling location for loose parts.
No Go to the next step.
4 Is a hissing noise present? Yes Inspect for the following:
• Vacuum leakage
• Spark plug looseness
• Intake-air system leakage
No Go to the next step.
5 Is a rapping or roar noise present? Yes Inspect looseness for followings:
• Dynamic dumper
• Intake-air system
• Exhaust system
No Go to the next step.
6 Is a knocking noise present? Yes Go to symptom troubleshooting “No.13 Knocking/
pinging”.
(See 01-03-37 NO.13 KNOCKING/PINGING-
ACCELERATION/CRUISE [MZI-3.5].)
No If the noise comes from the engine internal, inspect for
friction gear, timing chain or MLA noise.
7 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

01-03–48
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

End Of Sie

NO.22 VIBRATION CONCERNS (ENGINE) [MZI-3.5]

id0103d1802800

22
VIBRATION CONCERNS (ENGINE)
• Vibration from under hood or driveline
DESCRIPTION
• Loose attaching bolts or worn parts
POSSIBLE CAUSE
• Components malfunction such as worn parts

Diagnostic procedure 01-03

STEP INSPECTION RESULTS ACTION
1 Inspect the following components for loose Yes Inspect the following systems:
attaching bolts or worn parts: • Wheels
• Cooling fan • ATX
• Drive belt and pulleys • Driveline
• Generator • Suspension
• Engine mounts No Readjust or retighten engine mount installation
• Exhaust system mounts position.
All items normal? Service if necessary for other parts.
2 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie
NO.23 A/C DOES NOT WORK SUFFICIENTLY [MZI-3.5]
id0103d1802900

23
A/C DOES NOT WORK SUFFICIENTLY.
DESCRIPTION
A/C compressor magnetic clutch does not engage when the A/C switch is turned on.
• Improper refrigerant charging amount
• Open the A/C magnetic clutch
• Open circuit in wiring harness between A/C relay and A/C magnetic clutch
• Poor GND of A/C magnetic clutch
POSSIBLE CAUSE • Refrigerant pressure switch is stuck open.
• A/C relay is stuck open.
• Seized A/C compressor
• Open circuit in wiring harness between A/C switch and PCM through both refrigerant pressure switch
and A/C amplifier

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
2 Disconnect A/C compressor connector. Yes Inspect for GND condition of magnetic clutch on A/C
Start engine and turn A/C switch on. compressor.
Is there correct voltage at A/C compressor If GND condition is normal, inspect for open circuit
magnetic clutch terminal? magnetic clutch coil.
Specification No Go to the next step.
10.5 V or more
3 Disconnect refrigerant pressure switch Yes Inspect refrigerant pressure switch operation.
connector. If switch is normal, go to the next step.
Connect jumper wiring between A/C high No Inspect for the following:
pressure switch terminal. • A/C switch is stuck open.
Connect jumper wiring between refrigerant • Open circuit in wiring harness between refrigerant
pressure switch terminal. pressure switch and PCM terminal 1R
Turn the ignition switch to the ON position. • Open circuit in wiring harness between blower
Turn A/C switch on and set blower fan to any motor fan switch and resistor (if blower motor does
speed. not operate)
Does A/C work? • Evaporator temperature sensor and A/C amplifier

01-03–49
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
4 Remove jumper wiring from the switch Yes Inspect whether A/C relay is stuck open.
connector. Replace if necessary.
Reconnect connector to refrigerant pressure No Inspect the following and repair or replace if necessary:
switch. • Refrigerant charging amount
Start the engine and turn the A/C switch on. • A/C compressor for seizure
Does the fan operate?
5 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie
NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [MZI-3.5]
id0103d1803000

24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY.

DESCRIPTION A/C compressor magnetic clutch does not disengage.
• A/C compressor magnetic clutch engagement is stuck.
• A/C relay is stuck closed.
POSSIBLE CAUSE • Short to GND in wiring harness between A/C switch and PCM
• Short to GND in wiring harness between A/C relay and PCM
• Short circuit to battery power in A/C relay to magnetic clutch

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
No No DTC is displayed:
Are there any DTCs displayed?
Go to the next step.
2 Start the engine and idle it. Yes Inspect for the following:
Turn the A/C switch on. • A/C relay is stuck closed.
Remove the A/C relay. • Short to GND in wiring harness between A/C relay
Does the A/C magnetic clutch disengage? and PCM terminal 1N.
If both items normal, go to the next step.
No Inspect if circuit between the A/C relay and magnetic
clutch shorts to battery power circuit.
If the circuit is normal, inspect the magnetic clutch for
stuck engagement or clearance.
3 Disconnect refrigerant pressure switch Yes Inspect for short to GND in wiring harness between
connector. refrigerant pressure switch and PCM terminal 1R.
Start the engine and turn A/C switch on. No Go to the next step.
Note
• A/C should not work when disconnecting
connector. If A/C remains working, short
to GND circuit may be present.

Does the A/C remain working?

4 Reconnect refrigerant pressure switch Yes Inspect following:
connector. • Short to GND in wiring harness between A/C switch
Turn off A/C switch. and A/C amplifier
• Short to GND circuit between A/C amplifier and
Note refrigerant pressure switch
• A/C should not work when turning A/C No Inspect whether A/C switch is stuck closed.
switch off. If A/C remains working, short to
GND circuit may be present.

Does A/C remain working?

01-03–50
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
5 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
01-03

End Of Sie
NO.25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS [MZI-3.5]
id0103d1804200

25 A/C DOES NOT CUT OFF UNDER WOT CONDITIONS.

DESCRIPTION A/C compressor magnetic clutch does not disengage under WOT.
• Accelerator pedal position sensor malfunction
POSSIBLE CAUSE • Accelerator pedal position sensor misadjustment
• Loosely installed accelerator pedal position sensor

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Does A/C compressor disengage when the A/C Yes Go to the next step.
switch is turned off? No Go to symptom troubleshooting “No.24 A/C is always
on or A/C compressor runs continuously”.
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Inspect accelerator pedal position sensor.
3 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–51
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.26 EXHAUST SULPHUR SMELL [MZI-3.5]
id0103d1803200

26 EXHAUST SULPHUR SMELL

DESCRIPTION Rotten egg smell (sulphur) from exhaust
• Electrical connectors are disconnected or connected poorly
• Charcoal canister malfunction
• Vacuum lines are disconnected or connected improperly.
• Improper fuel pressure
• Poor fuel quality

Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair
procedures. Read following warnings before servicing fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
POSSIBLE CAUSE
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Are any driveability or exhaust smoke concerns Yes Go to the appropriate flow chart.
present? No Go to the next step.
2 Inspect the following: Yes Go to the next step.
• Electrical connections No Service if necessary.
• Vacuum lines Repeat Step 2.
• Fuel quality
Are all items normal?
3 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
4 Install the fuel pressure gauge between the fuel Yes Go to the next step.
pipe and the fuel distributor. No Low:
Start engine and idle it.
Inspect fuel pump relay and fuel pump circuit.
Is fuel line pressure correct at idle?
Inspect the fuel line for clogging.
(See 01-14-6 FUEL LINE PRESSURE
If there is no malfunction, replace the fuel pump
INSPECTION [MZI-3.5].)
unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
5 Inspect the charcoal canister for fuel saturation. Yes Replace the charcoal canister.
Is excess amount of liquid fuel present in No Inspect the fuel tank vent system.
canister? If the fuel tank vent system is normal, suggest trying a
different brand since sulphur content can vary in
different fuels.
If the fuel tank vent system is not normal, repair or
replace the malfunctioning part.

01-03–52
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
6 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
01-03

End Of Sie
NO.27 FUEL REFILL CONCERNS [MZI-3.5]
id0103d1803300

27 FUEL REFILL CONCERNS

DESCRIPTION • Fuel tank is not filled smoothly.
• Clogged EVAP pipes
• Nonreturn valve malfunction
• Improper use of fuel nozzle
• Inadequate fuel filling speed

Warning
• The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
— Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
POSSIBLE
— Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
CAUSE
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage to
fuel pipe and quick release connector. Always clean quick release connector joint area before
disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION ACTION
1 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
2 Remove the fuel-filler pipe. Yes Inspect for the following:
Make sure the nonreturn valve is installed • Improper use of fuel nozzle
properly. • Inadequate fuel filling speed
Inspect nonreturn valve operation. No Nonreturn valve is installed improperly:
Is the nonreturn valve normal?
• Reinstall nonreturn valve to proper position.
Nonreturn valve does not operate properly:
• Replace nonreturn valve.
3 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–53
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.28 FUEL FILLING SHUT OFF CONCERNS [MZI-3.5]
id0103d1912000

28 FUEL FILLING SHUT OFF CONCERNS

DESCRIPTION • Fuel does not shut off properly.
• Clogged EVAP pipes
• Nonreturn valve malfunction
• Fuel shut-off valve malfunction
• Fuel nozzle malfunction
• Fuel nozzle is not inserted correctly.

Warning
• The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
— Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
POSSIBLE keep sparks and flames away from fuel.
CAUSE — Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage to
fuel pipe and quick release connector. Always clean quick release connector joint area before
disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION ACTION
1 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC inspection.
(Engine off). (See 01-02-12 DTC TABLE [MZI-3.5].)
Retrieve any DTCs.
Are there any DTCs displayed?
No No DTC is displayed:
Go to the next step.
2 Remove the fuel-filler pipe. Yes Inspect for the following:
Make sure the nonreturn valve is installed • Improper use of fuel nozzle
properly. • Fuel is not inserted correctly.
Inspect nonreturn valve operation. • Inspect fuel shut-off valve.
Is the nonreturn valve normal? No Nonreturn valve is installed improperly:
• Reinstall the nonreturn valve to proper position.
Nonreturn valve does not operate properly:
• Replace the nonreturn valve.
3 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

01-03–54
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

NO.29 SPARK PLUG CONDITION [MZI-3.5]
id0103d1803600

29 SPARK PLUG CONDITION

DESCRIPTION Incorrect spark plug condition
Note
• Inspecting spark plugs condition can determine whether problem is related to a specific cylinder or
possibly all cylinders.
01-03
Wet/carbon stuck on specific plug:
• Spark—Weak, not visible
• Air/fuel mixture—Excessive fuel injection volume
• Compression—No compression, low compression
• Malfunction spark plug
Grayish white with specific plug:
• Air/fuel mixture—Insufficient fuel injection volume
• Malfunction spark plug
Wet/carbon is stuck on all plugs:
• Spark—Spark weak
• Air/fuel mixture—Too rich
• Compression—Low compression
• Clogging in intake/exhaust system
POSSIBLE CAUSE Grayish white with all plugs:
• Air/fuel mixture—Too lean

Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
(See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

Caution
• Disconnecting/connecting quick release connector without cleaning it may cause damage
to fuel pipe and quick release connector. Always clean quick release connector joint area
before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Remove all the spark plugs. Yes Troubleshooting completed.
Inspect spark plug condition. No Specific plug is wet or covered with carbon:
Is spark plug condition normal?
Go to the next step.
Specific plug looks grayish white:
Go to Step 7.
All plugs are wet or covered with carbon:
Go to Step 9.
All plugs look grayish white:
Go to Step 15.
2 Are the spark plug wet/covered with carbon by Yes Inspect all areas related to oil, working up and down.
the engine oil? No Go to the next step.
3 Inspect the spark plug for the following: Yes Go to the next step.
• Cracked insulator No Replace the spark plug.
• Heat range (See 01-18-3 SPARK PLUG REMOVAL/
• Air gap INSTALLATION [MZI-3.5].)
• Worn electrode
Is the spark plug normal?
4 Inspect compression pressure at suspected Yes Go to the next step.
malfunctioning cylinder. No Repair or replace the malfunctioning part.
Is compression pressure correct?
(See 01-10-9 COMPRESSION INSPECTION
[MZI-3.5].)

01-03–55
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
5 Install all spark plugs. Yes Go to the next step.
Perform the spark test at suspected No Repair or replace the malfunctioning part.
malfunctioning cylinder.
Is strong blue spark visible?
(Compare with normal cylinder.)
6 Install the fuel pressure gauge between fuel filter Yes Inspect fuel injector for the following:
and fuel distributor. • Open or short circuit in injector
Short check connector terminal F/P to body • Leakage
GND using a jumper wiring. • Injection volume
Turn the ignition switch to the ON position No Zero or low:
(Engine off).
Inspect the fuel pump relay and fuel pump circuit.
Is the fuel line pressure correct with the ignition
Inspect the fuel line for clogging.
switch at ON?
If there is no malfunction, replace the fuel pump
(See 01-14-6 FUEL LINE PRESSURE
unit.
INSPECTION [MZI-3.5].)
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
7 Inspect the spark plug for the following. Yes Go to the next step.
• Heat range No Replace the spark plug.
• Air gap (See 01-18-3 SPARK PLUG REMOVAL/
Is the spark plug normal? INSTALLATION [MZI-3.5].)
8 Remove the suspected fuel injector. Yes Inspect for open circuit in wiring harness between fuel
Inspect the following: injector connector terminal A and PCM at the following
• Resistance terminals:
• Fuel injection volume • For No.1 cylinder: 2BJ
(See 01-14-25 FUEL INJECTOR • For No.2 cylinder: 2BM
INSPECTION [MZI-3.5].) • For No.3 cylinder: 2BF
Are all above items normal? • For No.4 cylinder: 2BH
• For No.5 cylinder: 2BB
• For No.6 cylinder: 2BD
No Replace the fuel injector.
9 Is the air cleaner element free of clogging? Yes Go to the next step.
No Replace the air cleaner element.
10 Perform the spark test. Yes Go to the next step.
(See 01-03-60 ENGINE CONTROL SYSTEM No Repair or replace the malfunctioning part.
OPERATION INSPECTION [MZI-3.5].)
Is strong blue spark visible at each cylinder?
11 Install the fuel pressure gauge between the fuel Yes Go to the next step.
filter and fuel distributor. No Zero or low:
Short check connector terminal F/P to body
Inspect the fuel pump relay and fuel pump circuit.
GND using a jumper wiring.
Inspect the fuel line for clogging.
Turn the ignition switch to the ON position
If there is no malfunction, replace the fuel pump
(Engine off).
unit.
Is the fuel line pressure correct with ignition
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
switch at ON?
INSTALLATION [MZI-3.5].)
(See 01-14-6 FUEL LINE PRESSURE
INSPECTION [MZI-3.5].) High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
12 Inspect the following PIDs: Yes Go to the next step.
• ECT No Repair or replace the malfunctioning part.
• O2S11 (When engine can be started.)
• O2S12 (When engine can be started.)
• O2S21 (When engine can be started.)
• O2S22 (When engine can be started.)
• MAF
(See 01-40-5 PCM INSPECTION [MZI-3.5].)
Are PIDs normal?

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SYMPTOM TROUBLESHOOTING [MZI-3.5]

STEP INSPECTION RESULTS ACTION
13 Perform the purge control inspection. Yes Go to the next step.
(When engine can be started.) No Repair or replace the malfunctioning part.
(See 01-03-60 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [MZI-3.5].)
Is the purge control correct?
14 Perform compression inspection. Yes Visually inspect for deformed exhaust system part.
(See 01-10-9 COMPRESSION INSPECTION No Repair or replace the malfunctioning part. 01-03
[MZI-3.5].)
Is compression correct?
15 When the engine cannot be started, inspect the Yes Repair or replace the malfunctioning part.
intake-air system for air leakage. No Go to the next step.
When the engine can be started, perform intake
manifold vacuum inspection.
Is air sucked in from intake-air system?
16 Install the fuel pressure gauge between the fuel Yes Inspect the following PIDs:
filter and the fuel distributor. • ECT
Short check connector terminal F/P to body • O2S11
GND using a jumper wiring. • O2S12
Turn the ignition switch to the ON position • O2S21
(Engine off). • O2S22
Is fuel line pressure correct with the ignition • MAF
switch at ON? (See 01-40-5 PCM INSPECTION [MZI-3.5].)
(See 01-14-6 FUEL LINE PRESSURE Inspect PCM GND condition.
INSPECTION [MZI-3.5].) No Zero or low:
Inspect the fuel pump relay and fuel pump circuit.
Inspect the fuel line for clogging.
If there is no malfunction, replace the fuel pump
unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
High:
Replace the fuel pump unit.
(See 01-14-16 FUEL PUMP UNIT REMOVAL/
INSTALLATION [MZI-3.5].)
17 • Verify test results.
— If normal, return to diagnostic index to service any additional symptoms.
(See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair
or diagnosis.
• If vehicle is repaired, troubleshooting completed.
• If vehicle is not repaired or additional diagnostic information is not available, replace the PCM.
(See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

End Of Sie

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SYMPTOM TROUBLESHOOTING [MZI-3.5]

INTERMITTENT CONCERN TROUBLESHOOTING [MZI-3.5]
id0103d1800400
Vibration Method
• If malfunction occurs or becomes worse while driving on a rough road or when the engine is vibrating, perform
the steps below.

Note
• There are several reasons vehicle or engine vibration could cause an electrical malfunction. Inspect the
following:
— Connectors not fully seated
— Wiring harnesses not having full play
— Wiring harnesses laying across brackets or moving parts
— Wiring harnesses routed too close to hot parts
• An improperly routed, improperly clamped, or loose wiring harness can cause wiring to become pinched
between parts.
• The connector joints, points of vibration, and places where wiring harnesses pass such as through the
firewall and body panels are the major areas to be checked.

Inspection Method for Switch Connectors or Wiring Harnesses

1. Connect the M-MDS to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).

Note
• If the engine starts and runs, perform the following steps during idle.

3. Access PIDs for the switch you are inspecting.

4. Turn the switch on manually.
5. Slightly shake each connector or wiring harness
vertically and horizontally while monitoring the
PID.
• If PID value is unstable, inspect for poor
connection.

atraaw00000776

Inspection Method for Sensor Connectors or Wiring Harnesses

1. Connect the M-MDS to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).

Note
• If the engine starts and runs, perform the following steps during idle.

3. Access PIDs for the switch you are inspecting.

4. Slightly shake each connector or wiring harness
vertically and horizontally while monitoring the
PID.
• If PID value is unstable, inspect for poor
connection.

atraaw00000777

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SYMPTOM TROUBLESHOOTING [MZI-3.5]

Inspection Method for Sensors
1. Connect the M-MDS to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).

Note
• If the engine starts and runs, perform the following steps during idle.

3. Access PIDs for the switch you are inspecting. 01-03

4. Vibrate the sensor slightly with your finger.
• If PID value is unstable or malfunction occurs, check for poor connection or poorly mounted sensor or both.

Inspection Method for Actuators or Relays

1. Connect the M-MDS to the DLC-2.
2. Turn the ignition switch to the ON position (Engine off).

Note
• If the engine starts and runs, perform the following steps during idle.

3. Prepare the output state control function for actuators or relays that you are inspecting.
4. Vibrate the actuator or relay with your finger for 3
s after output state control function is activated.
• If variable click sound is heard, check for poor
connection or poorly mounted actuator or
both, or the relay.

Note
• Vibrating relays too strongly may result in
open relays.

atraaw00000778

Water Sprinkling Method

If malfunction occurs only under high humidity or rainy/snowy weather, perform the following steps:

Caution
• Indirectly change the temperature and humidity by spraying water onto the front of the radiator.
• If a vehicle is subject to water leakage, the leakage may damage the control module. When testing
a vehicle with a water leakage problem, special caution must be used.

1. Connect the M-MDS to the DLC-2 if you are inspecting sensors or switches.
2. Turn the ignition switch to the ON position (Engine off).

Note
• If the engine starts and runs, perform the following steps at idle.

3. Access PIDs for sensor or switch if you are inspecting sensors or switches.
4. If you are inspecting the switch, turn it on manually.
5. Spray water onto the vehicle or run it through a
car wash.
• If PID value is unstable or malfunction occurs,
repair or replace part if necessary.
End Of Sie

absggw00000793

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SYMPTOM TROUBLESHOOTING [MZI-3.5]

ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZI-3.5]
id0103d1803700
Input Signal System Inspection Procedure
1. Find an irregular signal. (See 01-03-60 Finding irregular signals.)
2. Locate source. (See 01-03-60 Locating the source of unusual signals.)
3. Repair or replace the malfunctioning part.
4. Confirm that the irregular signal is no longer detected.

Finding irregular signals

While referring to, use the PID/DATA monitor and record function to inspect the input signal system relating to the
problem.
1. Start the engine and idle the vehicle. You can assume that any signals that are out of specification by a wide
margin are irregular.
2. When recreating the problem, any sudden change in monitor input signals that is not intentionally created by
the driver can be determined as irregular.

Locating the source of unusual signals

Caution
• Compare the M-MDS monitor voltage with the measurement voltage using the digital
measurement system function. If you use another tester, misreading may occur.
• When measuring voltage, attach the tester GND to the GND of the PCM that is being tested, or to
the engine itself. If this is not performed, the measured voltage and actual voltage may differ.
• After connecting the pin to a waterproof coupler, confirming continuity and measuring the voltage,
inspect the waterproof connector for cracks. If there are any, use sealant to fix them. Failure to do
this may result in deterioration of the wiring harness or terminal from water damage, leading to
problems with the vehicle.

Variable resistance type 1 (TP sensor)

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Input signal system inspection for variable resistance type 1

1. When an irregular signal is detected, measure the #1 PCM terminal voltage.
• If the #1 terminal voltage and the M-MDS monitor voltage are the same, proceed to the next step.
• If there is a difference of 0.5 V or more, inspect for the following points concerning the PCM connector:
— Female terminal opening is loose.
— Coupler (pin holder) damage
— Pin discoloration (blackness)
— Harness/pin crimp is loose or disconnected.
2. Measure the #2 sensor terminal voltage.
• If there is a 0.5 V or more difference between the sensor and the M-MDS voltages, inspect the wiring
harness for open or short circuits.
• If the sensor and the M-MDS voltages are the same, inspect for the following points concerning the sensor
connector:
— Female terminal opening is loose.
— Coupler (pin holder) damage
— Pin discoloration (blackness)
• If there are no problems, proceed to next investigation below.

01-03–60
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

Standard power supply system inspection for variable resistance type 1
• Confirm that the #3 terminal is at 5 V.
— If the measured voltage on the #3 terminal is 5 V, inspect the following points on the sensor connector.
— If there is no problem, inspect for the following:
• Female terminal opening is loose.
• Coupler (pin holder) damage
• Pin discoloration (blackness)
— If the #3 terminal measures other than 5 V, inspect for the following: 01-03
• Open or short circuit in wiring harness
• Harness/pin crimp is loose or disconnected.

GND system inspection for variable resistance type 1

• Confirm that terminal sensor #5 is at 0 V.
— If it is at 0 V, inspect the sensor.
• If necessary, replace the sensor.
— If not, inspect for the following:
• Open or short circuit in wiring harness
• Female terminal opening is loose causing an open or short circuit in wiring harness
• Coupler (pin holder) damage
• Pin discoloration (blackness)
• Harness/pin crimp is loose or disconnected.

Variable resistance type 2 (mass air flow (MAF) sensor and VSS)

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GND system inspection for variable resistance type 2

• Confirm that terminal sensor #4 is at 0 V.
— If it is at 0 V, inspect the sensor.
• If necessary, replace the sensor.
— If not at 0 V, inspect for the following:
• Open circuit in wiring harness
• Female terminal opening is loose.
• Coupler (pin holder) damage
• Pin discoloration (blackness)
• Harness/pin crimp is loose or disconnected.

Input signal system inspection for variable resistance type 2

1. When an irregular signal is detected, measure the #1 PCM terminal voltage.
• If the #1 terminal voltage and the M-MDS monitor voltage are the same, proceed to the next step.
• If there is a difference of 0.5 V or more, inspect for the following points concerning the PCM connector:
— Female terminal opening is loose.
— Coupler (pin holder) damage
— Pin discoloration (blackness)
— Harness/pin crimp is loose or disconnected.
2. Measure the #2 sensor terminal voltage.
• If there is a 0.5 V or more difference between the sensor and the M-MDS voltages, inspect the wiring
harness for open or short circuits.
• If the sensor and the M-MDS voltages are the same, inspect the following points concerning the sensor
connector:
— Female terminal opening is loose.
— Coupler (pin holder) damage
— Pin discoloration (blackness)
— Harness/pin crimp is loose or disconnected.
• If there are no problems, proceed to next investigation below.

01-03–61
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

Electrical supply system inspection for variable resistance type 2
• Confirm that the sensor #3 terminal is B+.
— If the measured voltage on the #3 terminal is B+, inspect the following points on the sensor connector.
— If there is no problem, inspect for the following:
• Female terminal opening is loose.
• Coupler (pin holder) damage
• Pin discoloration (blackness)
— If the #3 terminal measures other than B+, inspect the following:
• Open or short circuit in wiring harness
• Harness/pin crimp is loose or disconnected.

Thermistor type (IAT sensor and CHT sensor)

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Input signal system inspection for thermistor type

1. When an irregular signal is detected, measure the #1 PCM terminal voltage.
• If the #1 terminal voltage and the M-MDS monitor voltage are the same, proceed to the next step.
• If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector:
— Female terminal opening loose
— Coupler (pin holder) damage
— Pin discoloration (blackness)
— Harness/pin crimp is loose or disconnected.
2. Measure the #2 sensor terminal voltage.
• If there is a 0.5 V or more difference between the sensor and the M-MDS voltages, inspect the wiring
harness for open or short circuits.
• If the sensor and the M-MDS voltages are the same, inspect the following points concerning the sensor
connector:
— Female terminal opening is loose.
— Coupler (pin holder) damage
— Pin discoloration (blackness)
— Harness/pin crimp is loose or disconnected.
• If there are no problems, proceed to next investigation below.

GND system inspection for thermistor type

• Confirm that terminal sensor #3 is at 0 V.
— If it is at 0 V, inspect the sensor. If necessary, replace the sensor.
— If not, inspect for the following:
• Open circuit in wiring harness
• Female terminal opening is loose.
• Coupler (pin holder) damage
• Pin discoloration (blackness)
• Harness/pin crimp is loose or disconnected.

Main Relay Operation Inspection

1. Verify that the main relay clicks when the ignition switch is turned to ON position and off.
• If there is no operation sound, inspect the following:
— Main relay (See 09-21-6 RELAY INSPECTION.)
— Harness and connector between battery and main relay terminal A.
— Harness and connector between PCM terminal 1Q and main relay terminal E.

01-03–62
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
SYMPTOM TROUBLESHOOTING [MZI-3.5]
Electronic Throttle Control System Inspection
Engine coolant temperature compensation inspection
1. Connect the M-MDS to the DLC-2.
2. Access the following PIDs:
• ECT
• IAT
• RPM
3. Verify that the engine is cold, then start the engine. 01-03
4. Verify that the engine speed decreases as the engine warms up.
• If the engine speed does not decrease or decreases slowly, inspect the following:
— CHT sensor and related wiring harness
(See 01-40-28 CYLINDER HEAD TEMPERATURE (CHT) SENSOR INSPECTION [MZI-3.5].)
— Electronic throttle body and related wiring harness
(See 01-13-7 THROTTLE BODY INSPECTION [MZI-3.5].)

Load compensation inspection

1. Start the engine and idle it.
2. Connect the M-MDS to the DLC-2.
3. Verify that P0506, P0507 is not displayed.
• If P0506, P0507 are displayed, perform DTC inspection.
(See 01-02-12 DTC TABLE [MZI-3.5].)
4. Access the RPM PID.

Note
• Excludes temporary idle speed drop just after the loads are turned on.

5. Verify that the engine speed is within the specification under each load condition.
• If load condition is not as specified, inspect the following:
— A/C switch and related wiring harness
(See 07-40-23 FRONT CLIMATE CONTROL UNIT INSPECTION.)
— Fan switch and related wiring harness
(See 07-40-23 FRONT CLIMATE CONTROL UNIT INSPECTION.)

Throttle position (TP) sweep inspection

1. Connect the M-MDS to the DLC-2.
2. Turn the ignition switch to the ON position.
3. Verify that none of the following DTC are displayed:
• P0122, P0123, P0222, P0223, P2101, P2107, P2112, P2122, P2123, P2127, P2128, P2135
— If any one DTC is displayed, perform DTC inspection.
4. Access TP1, TP2 PID.
5. Verify that the PID reading is within the CTP value. (See 01-40-5 PCM INSPECTION [MZI-3.5].)
• If the PID reading is out of range, perform the following:
— Remove the air duct from the throttle valve body.
— Verify that the throttle valve opens when the accelerator pedal is depressed.
• If the throttle valve opens, inspect the throttle position sensor and related wiring harness.
• If the throttle valve does not open, inspect the throttle actuator control motor and related wiring
harness.
6. Gradually depress the throttle pedal and verify that the PID reading increases accordingly.
• If the PID reading drops momentarily, inspect the following:
— Throttle position sensor
7. Fully depress the throttle pedal and verify that the PID reading is within WOT value. (See 01-40-5 PCM
INSPECTION [MZI-3.5].)
• If the PID reading is out of range, perform the followings:
— Remove the air duct from throttle valve body.
— Verify that the throttle valve opens when throttle pedal is depressed.
• If the throttle valve opens, inspect the throttle position sensor and related wiring harness.
• If the throttle valve does not open, inspect the throttle actuator control motor and related wiring
harness.

Revised 1/2007 (Ref. No. R009/07) 01-03–63

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
SYMPTOM TROUBLESHOOTING [MZI-3.5]
Fuel Injector Operation Inspection
STEP INSPECTION RESULTS ACTION
1 While cranking the engine, inspect for fuel Yes Fuel injector operation is normal.
injector operation sound at each cylinder using a No All cylinders not heard:
soundscope. Go to the next step.
Is operation sound heard?
Some cylinders not heard:
Go to Step 3.
2 Perform main relay operation inspection. Yes Inspect the following:
Is main relay operation normal? • Fuel injector power system related wiring harness
and connectors
• PCM connectors
• Fuel injector GND and related wiring harness and
connectors
No Repair or replace malfunctioning parts.
3 Switch fuel injector connector of not operating Yes Go to the next step.
fuel injector with operating fuel injector. No Replace the fuel injector.
Is operation sound heard?
4 Are wiring harness and connectors of not Yes Inspect PCM terminal voltage of fuel injector signal.
operation fuel injector normal? (Open or short) No Repair or replace malfunctioning parts.

Fuel Cut Control System Inspection

Note
• This inspection has to perform after the Fuel Injector Operation Inspection.
If simulation function of the M-MDS is used:
1. Warm up the engine and idle it.
2. Connect the M-MDS to the DLC-2.
3. Select the RPM and FUELSYS1 PIDs.
4. Monitor the both PIDs while performing the following steps.
(1) Depress the accelerator pedal and increase the RPM PID to 4,000 rpm.
(2) Quickly release the accelerator pedal (brake pedal is not depressed) and verify that the FUELSYS1 PID is
OL, and CL. when the RPM PID drops below 1,200 rpm.
• If not as specified, inspect the following.
— CHT sensor and related harness
(See 01-40-28 CYLINDER HEAD TEMPERATURE (CHT) SENSOR INSPECTION [MZI-3.5].)
— TR switch and related wiring harness
(See 05-17-13 TRANSAXLE RANGE (TR) SWITCH INSPECTION [AW6A-EL, AW6AX-EL].)
If simulation function of the M-MDS is not used:
1. Warm up the engine and idle it.
2. Measure the fuel injector control signal wave profile using the oscilloscope while performing the following steps.
(1) Depress the accelerator pedal and increase the engine speed to 4,000 rpm.
(2) Quickly release the accelerator pedal (brake pedal is not depressed) and verify that the wave profile
constant B+, and appears wave, when the engine speed drops below 2,200 rpm.
• If not as specified, inspect the following.
— CHT sensor and related harness
(See 01-40-28 CYLINDER HEAD TEMPERATURE (CHT) SENSOR INSPECTION [MZI-3.5].)
— TR switch and related wiring harness
(See 05-17-13 TRANSAXLE RANGE (TR) SWITCH INSPECTION [AW6A-EL, AW6AX-EL].)
Fuel Pump Operation Inspection
1. Remove the fuel-filler cap.
2. Turn the ignition switch to the ON position.
3. Turn the fuel pump relay from off to on using the FP PID and inspect if the operation sound is heard.
• If no operation sounds is heard, proceed to next step.
4. Measure voltage at wiring harness side fuel pump connector terminal B.
Specification
B+ (Ignition switch at on)
• If the voltage is as specified, inspect the following:
— Fuel pump continuity
— Fuel pump GND
— Wiring harness between fuel pump relay and PCM terminal 1V
• If not as specified, inspect the following:
— Fuel pump relay
— Wiring harness connector (Main relay—fuel pump relay—fuel pump)
01-03–64
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SYMPTOM TROUBLESHOOTING [MZI-3.5]

Fuel Pump Control System Inspection
1. Crank the engine and verify that fuel pump relay operation sound is heard.
2. If operation sound is not heard, inspect the following:
• Fuel pump relay
(See 09-21-6 RELAY INSPECTION.)
• Wiring harness and connectors (Main relay—fuel pump relay—PCM terminal 1V)

Spark Test 01-03

1. Disconnect the fuel pump relay.
2. Verify that each ignition coil and connector is connected properly.
3. Inspect the ignition system in the following procedure.

Warning
• High voltage in the ignition system can cause strong electrical shock which can result in serious
injury. Avoid direct contact to the vehicle body during the following spark test.

STEP INSPECTION ACTION

1 • Disconnect the ignition coil from the spark Yes Go to the next step.
plugs. No Perform 2 times of no-load racing at 4000rpm for 2 min to
• Remove the spark plugs. burn off the carbon deposits.
— Ensure that the spark plugs don't have Then repeat this step.
carbon deposits.
• Are the spark plugs OK?
2 • Inspect the spark plugs for damage, wear, Yes Go to the next step.
and proper plug gap. No Replace spark plugs, then go to the next step.
• Are the spark plugs normal?
3 • Reconnect the spark plugs to the ignition Yes Ignition system is normal.
coil. No Some cylinders do not spark:
• Ground the spark plugs to the engine.
• Go to the next step.
• Is a strong blue spark visible at each cylinder
while cranking? All cylinders do not spark:
• Go to Step 5.
4 • Inspect the following wiring harnesses for Yes Inspect and replace the ignition coil.
open or short: (See 01-18-2 IGNITION COIL INSPECTION [MZI-3.5].)
— Ignition coil No.1 terminal C—PCM No Repair or replace the malfunctioning part, then go to Step 1.
terminal 2A
— Ignition coil No.2 terminal C—PCM
terminal 2F
— Ignition coil No.3 terminal C—PCM
terminal 2K
— Ignition coil No.4 terminal C—PCM
terminal 2W
— Ignition coil No.5 terminal C—PCM
terminal 2AA
— Ignition coil No.6 terminal C—PCM
terminal 2AE
• Are the wiring harnesses normal?
5 • Measure the voltage at terminal A in each Yes Go to the next step.
ignition coils. No Inspect power supply circuit of ignition coils.
• Is the voltage B+?
6 Verify continuity between each ignition coils Yes Go to the next step.
terminal B and battery negative post. No Inspect GND circuit of ignition coils.
Is there any continuity?
7 • Does the PCM connector or ignition coil Yes Repair or replace the connector, then go to Step 1.
connectors have poor connection? No Go to the next step.
8 • Are the following parts normal? Yes Inspect for open or short circuit in wiring harness and
— CKP sensor and crankshaft pulley connector of CKP sensor.
No Repair or replace the malfunctioning part, then go to Step 1.

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SYMPTOM TROUBLESHOOTING [MZI-3.5]

Purge Control System Inspection
If simulation function of the M-MDS is used:
1. Start the engine.
2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.
3. Put the finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold.
• If there is a vacuum, inspect the following:
— Wiring harness and connectors (Purge solenoid valve—PCM terminal 1BC)
— Purge solenoid vale (stuck open)
4. Connect the M-MDS to the DLC-2 and verify that the DTC P0443 is shown. Perform the DTC inspection.
(See 01-02-12 DTC TABLE [MZI-3.5].)
5. Select EVAPCP PID.
6. Increase the duty value of the purge valve to 50 % and inspect if the operation sound of the valve is heard.
• If the operation sound is heard, inspect for the loose or damaged vacuum hose. (Intake manifold—purge
solenoid valve—charcoal canister)
• If the operation sound is not heard, perform the purge solenoid valve inspection.
(See 01-16-8 PURGE SOLENOID VALVE INSPECTION [MZI-3.5].)
7. Warm up the engine to normal operating temperature.
8. Monitor the EVAPCP PID using the M-MDS, and drive the vehicle approx. 2,000 rpm for 30 sec. or more.
• If the EVAPCP PID is 0 %, inspect the following.
— MAF, APP1, APP2, APP3, TP_REL and LOAD PIDs.

If simulation function of the M-MDS is not used:

1. Start the engine.
2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.
3. Put the finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold.
• If there is a vacuum, inspect the following:
— Wiring harness and connectors (Purge solenoid valve—PCM terminal 1BC)
— Purge solenoid vale (stuck open)
4. Connect the M-MDS to the DLC-2 and verify that the DTC P0443 is shown. Perform the DTC inspection.
(See 01-02-12 DTC TABLE [MZI-3.5].)
5. Access EVAPCP and ECT PIDs.
6. Verify that the ECT PID is more than 78 °C {173 °F}.
• If the ECT PID reading indicates less than 78 °C {173 °F}, perform the ECT inspection.
7. Set the vehicle on the dynamometer or chassis roller.

Warning
• When the dynamometer or chassis roller is operating, there is a possibility that the operator may
come into contact with or be caught up in the rotating parts, leading to serious injuries or death.
When performing work while the dynamometer or chassis roller is operating, be careful not to
come into contact with or caught up in any of the rotating parts.

8. Drive the vehicle approx. 2,000 rpm for 30 sec. or more.

• If there is no vacuum, inspect the following:
— Wiring harness and connector (Main relay—purge solenoid valve—PCM terminal 1BC)
— Purge solenoid valve
— MAF, APP1, APP2, APP3, TP_REL and LOAD PISs
• If there is vacuum, inspect the following:
— Vacuum hose (Purge solenoid valve—charcoal canister)

A/C Cut-off Control System Inspection

1. Start the engine.
2. Turn the A/C switch and the fan switch on.
3. Verify that the A/C compressor magnetic clutch actuates.
• If it does not actuate, go to symptom troubleshooting “No.23 A/C does not work sufficiently“.
4. Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2—5 s.
• If it actuates, inspect as follows:
— A/C relay
— Open or short to GND circuit in wiring harness and connectors (Ignition switch—A/C relay—PCM
terminal 1N)
— A/C related parts
— APP1, APP2, APP3 PIDs

01-03–66
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
SYMPTOM TROUBLESHOOTING [MZI-3.5]
Cooling Fan Control System Inspection
1. Connect the M-MDS to the DLC-2.
2. Start the engine and warm it up to normal operating temperature.
3. Perform the KOER self-test. (See 01-02-8 KOEO/KOER SELF TEST [MZI-3.5].)
4. Verify that the DTC P0480 is not shown and the cooling fan operates during the KOER self-test.
• If DTC P0480 is shown, perform the DTC troubleshooting procedure.
(See 01-02-12 DTC TABLE [MZI-3.5].)
• If the cooling fans do not operate, proceed to the following: 01-03
1. Verify the clicking sound of the cooling fan relay when the ignition switch is turned from the off to the ON
position.
2. If there is no the clicking sound, inspect the cooling fan relay for an open circuit between the ignition
switch and the cooling fan relay.
• If there is a clicking sound, go to the next step.
• Inspect the following parts in the indicated order in accordance with fan operation conditions.
Cooling fans do not operate
— Open circuit between the fan control module and the cooling fan relay
— Open circuit between fan control module and ground
— Poor connection of the fan control module connector
— Fan control module (See 01-12-16 FAN CONTROL MODULE INSPECTION [MZI-3.5].)
Cooling fan motor No.1 does not operate
— Open or short to ground circuit between the fan control module and cooling fan motor No.1
— Poor connection of the fan control module connector or cooling fan motor No.1 connector
— Cooling fan motor No.1 (See 01-12-16 FAN MOTOR INSPECTION [MZI-3.5].)
— Fan control module (See 01-12-16 FAN CONTROL MODULE INSPECTION [MZI-3.5].)
Cooling fan motor No.2 does not operate
— Open or short to ground circuit between the fan control module and the cooling fan motor No.2
— Poor connection of the fan control module connector or the cooling fan motor No.1 connector
— Cooling fan motor No.2 (See 01-12-16 FAN MOTOR INSPECTION [MZI-3.5].)
— Fan control module (See 01-12-16 FAN CONTROL MODULE INSPECTION [MZI-3.5].)
Variable Valve Timing Control System Operation Inspection
When idling cannot be continued

Note
• Inspect for each bank

1. Remove the OCV and verify that the spool valve is at maximum retard position.
• If the spool valve is stuck in advance direction, replace the OCV. (See 01-10-55 OIL CONTROL VALVE
(OCV) REMOVAL/INSTALLATION [MZI-3.5].)
2. Connect the OCV.
3. Turn the ignition switch to ON position.
4. Verify that the spool valve is at max. retard position.
• If the spool valve is stuck in advance direction, inspect the following:
— Short circuit in harnesses or connectors between the OCV and the PCM.
5. Inspect the variable valve timing actuator.

When idling can be continued

For right bank
1. Disconnect OCV (RH) connector.
2. Warm up the engine and it at idle.
3. Apply the battery voltage to the OCV and verify that the engine idles roughly or stalls.
• If the engine idles roughly or stalls, inspect the timing belt component (valve timing deviation).
• If the engine does not idle roughly or stall, go to the next step.
4. Remove the OCV (RH) and perform spool valve operation inspection. (See 01-10-55 OIL CONTROL VALVE
(OCV) REMOVAL/INSTALLATION [MZI-3.5].)
• If not as specified, inspect the following:
— OCV (RH)
— Harnesses and connectors between OCV (RH) and PCM have an open or short circuit.
• If as specified, inspect the following right bank hydraulic passages for clogging or leakage, or both.
— Oil pressure switch - OCV
— OCV - camshaft
— Camshaft internal passage
5. If they are normal, replace the right bank camshaft pulley (with built-in variable valve timing actuator).

Revised 1/2007 (Ref. No. R009/07) 01-03–67

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
SYMPTOM TROUBLESHOOTING [MZI-3.5]
When idling can be continued
For left bank
1. Disconnect OCV (LH) connector.
2. Warm up the engine to idle.
3. Apply the battery voltage to the OCV and verify that the engine idles roughly or stalls.
• If the engine idles roughly or stalls, inspect the timing belt component (valve timing deviation).
• If the engine does not idle roughly or stall, go to the next step.
4. Remove the OCV (LH) and perform spool valve operation inspection. (See 01-10-55 OIL CONTROL VALVE
(OCV) REMOVAL/INSTALLATION [MZI-3.5].)
• If not as specified, inspect the following:
— OCV (LH)
— Harnesses and connectors between OCV (LH) and PCM have an open or short circuit.
• If as specified, inspect the following left bank hydraulic passages for clogging or leakage or both.
— Oil pressure switch - OCV
— OCV - camshaft
— Camshaft internal passage
5. If they are normal, replace the left bank camshaft pulley (with built-in variable valve timing actuator).

Evaporative Emission (EVAP) System Leak Inspection

• To verify that the problem has been fixed properly after repairs, the run drive cycle or EVAP system leak
inspection must be performed.

EVAP system leak inspection using leak tester

1. Perform the following SST (EVAP System Tester 134-01049) self-test:

Note
• If the tester does not work correctly during the self-test, refer to the tester operators manual for a more
detailed self-test procedure.

(1) Verify that the control valve on the panel is in

the HOLD position then open the nitrogen PRESSURE VALVE "TEST AND HOLD"
GAUGE
bottle valve.
(2) Connect the vehicle interface hose (part of
the SST) to the SELF-TEST port located on
the control panel. Hand tighten the fitting. (Do
not overtighten.)
(3) Turn the control valve to the TEST position.
(4) The gauge should read 331—381 mm {13—
15 in} of water.
• If the gauge is not reading in this range,
SELF-TEST
adjust the pressure by turning the black
PORT
knob on the low pressure regulator at the
nitrogen bottle.
(5) Turn the control valve to the HOLD position.
(6) Verify that the gauge holds pressure and that .020 TEST .040 TEST
the flow meter reads no flow. PORT PORT
• If there is no drop in pressure and no flow, ac9uuw00001083
the tester passes the self-test.
• If the gauge leaks down, refer to the tester
operators manual.

01-03–68
1890-1U-06H(01-03).fm 69 ページ ２００６年１２月１９日　火曜日　午前１０時２８分

SYMPTOM TROUBLESHOOTING [MZI-3.5]

2. Connect the SST to the vehicle.
(1) Verify that the control valve on the panel is in the HOLD position then open the nitrogen bottle valve.
(2) Remove the fuel-filler cap from the vehicle.
• If the fuel-filler cap is not a MAZDA part or equivalent, replace it.

Note
• INSPECT FUEL FILLER CAP AND FILLER NECK
— Visually inspect for damage, insufficient sealing, rust, cracks or warps for filler cap and filler neck. 01-03
— Repair or replace if necessary.

(3) Connect the receiver assembly (SST: CAP ADAPTER VEHICLE CAP
AKS441130) to the vehicle cap test hose TEST HOSE
assembly (part of the SST) and the fuel-filler ASSEMBLY
cap from the vehicle.
(4) Connect the cap adaptor (SST: AKS441131) VEHICLE
INTERFACE
to the vehicle cap test hose assembly (part of
HOSE
the SST) and to the fuel-filler neck.
(5) Connect the vehicle interface hose (part of
the SST) to the center fitting of the vehicle cap
test hose assembly (part of the SST).
RECEIVER
3. Connect the M-MDS to the DLC-2. ASSEMBLY
4. Turn the ignition switch to the ON position (Engine
ac9uuw00001084
off).
5. Request the PCM on-board device control (Mode
08) using the M-MDS to close the canister vent value.

Note
• The canister vent value is closed for 10 min unless the following any actions are done:
— The engine is started.
— The ignition switch is turned off position.

6. Make sure the control valve on the 134-01049 is in the HOLD position and that the valve on the cylinder of
nitrogen gas is open.
7. Turn the control valve to the open position and let the system fill. You should note a drop in the gauge pressure
along with the flow meter being pegged at maximum flow for several minutes depending on how full or empty
the fuel tank is, and how long it takes to completely fill and pressurize the evaporative emissions system hoses.
8. If the gauge and the flow meter do not settle to a measurable level after 2—3 min, then refer to the Mazda
Workshop Manual to verify that the canister vent valve is properly closed. If canister vent valve is properly
closed. The EVAP system has large leakage. Check for leakage and repair as necessary.
9. Verify the pressure gauge and flow meter reading to determine if there is an evaporative emissions leak:
NO EVAPORATIVE LEAK:
• The flow meter registers “zero flow” and the pressure gauge returns to the pre-set pressure of 356 mm {14
in} of water (H2O).
EVAPORATIVE LEAK:
• The pressure does not return to the preset level of 356 mm {14 in} of water (H2O) when measuring the
flow. See “SETTING LEAK STANDARD FOR TESTING” (.020 to.040 inch H2O) of the Evaporative
Emissions Tester operators manual (134-01067).

Note
• Turn the control valve to the HOLD position then disconnect the SST.

End Of Sie

01-03–69
1890-1U-06H(01-10).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
01-10 MECHANICAL [MZI-3.5]
MECHANICAL LOCATION INDEX Cylinder Head Removal Note . . . . . . . . 01-10–28
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-10–2 Cylinder Head Installation Note. . . . . . . 01-10–29
ENGINE COVER Camshaft Component
REMOVAL/INSTALLATION Installation Note . . . . . . . . . . . . . . . . . 01-10–29
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-10–3 FRONT OIL SEAL REPLACEMENT
DRIVE BELT INSPECTION [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-10–32 01-10
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-10–4 Crankshaft Pulley Lock Bolt
Generator and A/C Drive Belt . . . . . . . 01-10–4 Removal Note . . . . . . . . . . . . . . . . . . . 01-10–34
Power Steering Oil Pump No.3 Engine Mount
Drive Belt . . . . . . . . . . . . . . . . . . . . . . 01-10–4 Removal Note . . . . . . . . . . . . . . . . . . . 01-10–34
DRIVE BELT REMOVAL/INSTALLATION Crankshaft Pulley
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-10–4 Removal Note . . . . . . . . . . . . . . . . . . . 01-10–36
Generator and A/C drive belt . . . . . . . . 01-10–4 Front Oil Seal Removal Note. . . . . . . . . 01-10–37
Power Steering Oil Pump Front Oil Seal Installation Note . . . . . . . 01-10–37
Drive Belt . . . . . . . . . . . . . . . . . . . . . . 01-10–5 Crankshaft Pulley
DRIVE BELT AUTO TENSIONER Installation Note . . . . . . . . . . . . . . . . . 01-10–37
INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-10–7 No.3 Engine Mount
VALVE CLEARANCE Installation Note . . . . . . . . . . . . . . . . . 01-10–38
INSPECTION/ADJUSTMENT Crankshaft Pulley Lock Bolt
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-10–7 Installation Note . . . . . . . . . . . . . . . . . 01-10–39
Valve Clearance Inspection . . . . . . . . . 01-10–7 REAR OIL SEAL REPLACEMENT
Valve Clearance Adjustment . . . . . . . . 01-10–9 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-10–40
COMPRESSION INSPECTION Rear Oil Seal Removal Note . . . . . . . . . 01-10–40
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-10–9 Rear Oil Seal Installation Note . . . . . . . 01-10–40
TIMING CHAIN ENGINE REMOVAL/INSTALLATION
REMOVAL/INSTALLATION [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-10–41
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-10–11 No.1 Engine Mount
Crankshaft Pulley Lock Bolt Removal Note . . . . . . . . . . . . . . . . . . . 01-10–43
Removal Note . . . . . . . . . . . . . . . . . . 01-10–13 No.3 Engine Mount Rubber and No.4
Crankshaft Pulley Engine Mount Bracket
Removal Note . . . . . . . . . . . . . . . . . . 01-10–13 Removal Note . . . . . . . . . . . . . . . . . . . 01-10–43
Front Oil Seal Removal Note . . . . . . . . 01-10–13 Engine and Transaxle
Cylinder Head Cover Removal Note . . . . . . . . . . . . . . . . . . . 01-10–44
Removal Note . . . . . . . . . . . . . . . . . . 01-10–14 Engine Mount Installation Note . . . . . . . 01-10–44
Cylinder Head Cover Oil Seal ENGINE DISASSEMBLY/ASSEMBLY
Removal Note . . . . . . . . . . . . . . . . . . 01-10–14 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-10–46
Engine Front Cover and No.3 Engine No.3 Engine Mount Stay (Engine
Mount Bracket Removal Note . . . . . . 01-10–15 Front Cover Side)
OCV Component Removal Note . . . . . 01-10–15 Installation Note . . . . . . . . . . . . . . . . . 01-10–48
Timing Chain Component Water Inlet Pipe Installation Note . . . . . 01-10–48
Removal Note . . . . . . . . . . . . . . . . . . 01-10–16 VARIABLE VALVE TIMING ACTUATOR
OCV Component REMOVAL/INSTALLATION
Installation Note . . . . . . . . . . . . . . . . . 01-10–17 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-10–48
Timing Chain Component Variable Valve Timing Actuator
Installation Note . . . . . . . . . . . . . . . . . 01-10–17 Component Removal Note . . . . . . . . . 01-10–50
Engine Front Cover and No.3 Engine Variable Valve Timing Actuator
Mount Bracket Installation Note . . . . . 01-10–19 Component Installation Note. . . . . . . . 01-10–53
Cylinder Head Cover Oil Seal OIL CONTROL VALVE (OCV)
Installation Note . . . . . . . . . . . . . . . . . 01-10–20 REMOVAL/INSTALLATION
Cylinder Head Cover [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-10–55
Installation Note . . . . . . . . . . . . . . . . . 01-10–21 OIL CONTROL VALVE (OCV)
Front Oil Seal Installation Note . . . . . . 01-10–22 INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-10–55
Crankshaft Pulley Coil Resistance Inspection . . . . . . . . . . 01-10–55
Installation Note . . . . . . . . . . . . . . . . . 01-10–22 Spool Valve
Crankshaft Pulley Lock Operation Inspection . . . . . . . . . . . . . . 01-10–56
Bolt Installation Note . . . . . . . . . . . . . 01-10–23 ENGINE TUNE-UP [MZI-3.5] . . . . . . . . . . 01-10–57
CYLINDER HEAD GASKET Engine Tune-up Preparation . . . . . . . . . 01-10–57
REPLACEMENT [MZI-3.5] . . . . . . . . . . 01-10–23 Ignition Timing Inspection . . . . . . . . . . . 01-10–57
Camshaft Component Idle Speed Inspection . . . . . . . . . . . . . . 01-10–57
Removal Note . . . . . . . . . . . . . . . . . . 01-10–25 Idle Mixture Inspection . . . . . . . . . . . . . 01-10–57

End of Toc

01-10–1
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MECHANICAL [MZI-3.5]
MECHANICAL LOCATION INDEX [MZI-3.5]
WM: ENGINE COMPLETE

id0110c1800100

6
1

3 2

11

12
5
11
12

8
7

10

9
ac9uuw00000193

1 Engine cover 2 Generator and A/C drive belt

(See 01-10-3 ENGINE COVER REMOVAL/ (See 01-10-4 DRIVE BELT INSPECTION [MZI-3.5].)
INSTALLATION [MZI-3.5].) (See 01-10-4 DRIVE BELT REMOVAL/
INSTALLATION [MZI-3.5].)

01-10–2
1890-1U-06H(01-10).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
3 Power steering oil pump drive belt 8 Cylinder head gasket
(See 01-10-4 DRIVE BELT INSPECTION [MZI-3.5].) (See 01-10-23 CYLINDER HEAD GASKET
(See 01-10-4 DRIVE BELT REMOVAL/ REPLACEMENT [MZI-3.5].)
INSTALLATION [MZI-3.5].) 9 Front oil seal
4 Drive belt auto tensioner (See 01-10-32 FRONT OIL SEAL REPLACEMENT
(See 01-10-7 DRIVE BELT AUTO TENSIONER [MZI-3.5])
INSPECTION [MZI-3.5].) 10 Rear oil seal
5 Tappet (See 01-10-40 REAR OIL SEAL REPLACEMENT 01-10
(See 01-10-7 VALVE CLEARANCE INSPECTION/ [MZI-3.5])
ADJUSTMENT [MZI-3.5].) 11 Variable valve timing actuator
6 Engine (See 01-10-48 VARIABLE VALVE TIMING
(See 01-10-9 COMPRESSION INSPECTION [MZI- ACTUATOR REMOVAL/INSTALLATION [MZI-3.5].)
3.5].) 12 OCV
(See 01-10-41 ENGINE REMOVAL/INSTALLATION (See 01-10-55 OIL CONTROL VALVE (OCV)
[MZI-3.5].) REMOVAL/INSTALLATION [MZI-3.5].)
(See 01-10-46 ENGINE DISASSEMBLY/ (See 01-10-55 OIL CONTROL VALVE (OCV)
ASSEMBLY [MZI-3.5].) INSPECTION [MZI-3.5].)
(See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
7 Timing chain
(See 01-10-11 TIMING CHAIN REMOVAL/
INSTALLATION [MZI-3.5].)

End Of Sie
ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5]
WM: PLUG HOLE PLATE

id0110c1804300
1. Remove the engine cover in the order indicated in the figure.

Note
• Firmly pull the engine cover near the locations shown to disengage the retainers.

2. Install in the reverse order of removal.

End Of Sie
WM: DRIVE BELT

1
2

1 INSTALLATION
AREA ON
ENGINE 2 RETAINER
COVER SIDE

INSTALLATION
INSTALLATION
AREA ON
AREA ON
ENGINE SIDE
ENGINE SIDE

ac9uuw00000168

01-10–3
1890-1U-06H(01-10).fm 4 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
DRIVE BELT INSPECTION [MZI-3.5]
id0110c1801500
Generator and A/C Drive Belt

Note
• The generator and A/C drive belt deflection/tension inspection is not necessary because of the use of the
drive belt auto tensioner.

1. Verify that the drive belt auto tensioner indicator mark does not exceed the maximum belt length.
• If it exceeds the maximum belt length, replace the generator and A/C drive belt. (See 01-10-4 DRIVE BELT
REMOVAL/INSTALLATION [MZI-3.5].)
2. Visually inspect the generator and A/C drive belt
for damage and cracks. VIEW A NOMINAL BELT MINIMUM BELT
LENGTH
• If there is generator and A/C drive belt LENGTH
damage and cracks, replace the generator
and A/C drive belt. (See 01-10-4 DRIVE BELT
REMOVAL/INSTALLATION [MZI-3.5].)

MAXIMUM BELT INDICATOR

LENGTH MARK
A

ac9uuw00000197

Power Steering Oil Pump Drive Belt

1. Visually inspect the power steering oil pump drive belt for damage and cracks.
• If there is power steering oil pump drive belt damage and cracks, replace the power steering oil pump drive
belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-3.5].)
End Of Sie
DRIVE BELT REMOVAL/INSTALLATION [MZI-3.5]
id0110c1801600
Generator and A/C drive belt

Note
• When removing the generator and A/C drive belt, perform the procedure with two people, one releasing
the belt tension and the other removing the belt.

1. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the front wheel and tire (RH). (See 02-10-1 GENERAL PROCEDURES (SUSPENSION).)
3. Remove the splash shield (RH).

01-10–4
1890-1U-06H(01-10).fm 5 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
4. Set a breaker bar on the center of the tensioner
pulley as shown. BREAKER
5. Using the breaker bar, turn the center of the BAR
tensioner pulley clockwise to release the tension
on the generator and A/C drive belt.
6. Remove the generator and A/C drive belt. DRIVE BELT
7. Install the generator and A/C drive belt. AUTO
TENSIONER
01-10
Note
• When the generator and A/C drive belt is
replaced with a new one, the drive belt auto
tensioner indicator mark is aligned with the
ac9uuw00000198
nominal belt length mark.

8. Verify that the drive belt auto tensioner indicator

mark is within the maximum and minimum belt VIEW A NOMINAL BELT MINIMUM BELT
LENGTH LENGTH
length. (See 01-10-4 DRIVE BELT INSPECTION
[MZI-3.5].)
• If the drive belt auto tensioner indicator mark
is not within the limit, replace the generator
and A/C drive belt.
9. Install the splash shield (RH).
10. Install the front wheel and tire (RH). (See 02-10-1
GENERAL PROCEDURES (SUSPENSION).)
11. Install the engine cover. (See 01-10-3 ENGINE MAXIMUM BELT INDICATOR
COVER REMOVAL/INSTALLATION [MZI-3.5].) LENGTH MARK
A

ac9uuw00000197

Power Steering Oil Pump Drive Belt

1. Remove the generator and A/C drive belt. (See 01-10-4 Generator and A/C drive belt.)
2. Remove the power steering oil pump drive belt.
(1) Install the SST between the power steering oil
pump drive belt and the power steering oil
pump pulley.
49 UN30 312521
Note
• Hold the SST by hand until it is lodges
between the power steering oil pump pulley
and power steering oil pump drive belt.

(2) Turn the crankshaft clockwise to remove the

power steering oil pump drive belt.
ac9uuw00000275
Note
• If there is power steering oil pump drive belt
damage and cracks, replace the power steering oil pump drive belt.

01-10–5
1890-1U-06H(01-10).fm 6 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
3. Install the power steering oil pump drive belt.
(1) Install the SST according to the following steps.
1) Loosen the clamp adapter nut of the SST.

Note
• There is no need to remove the clamp adapter nut completely when positioning the SST on the power
steering oil pump pulley.

2) Position the SST on the power steering oil

pump pulley with the clamp adapter in one
of the holes of the pulley.
3) Tighten the clamp adapter nut by hand. 49 UN30 312523

Note
• Hand tightening of the clamp adapter nut is
sufficient.

POWER STEERING
OIL PUMP PULLEY

CLAMP ADAPTER
49 UN30 312523
CLAMP ADAPTER NUT

ac9uuw00001875

(2) Position the power steering oil pump drive belt

around the SST and the power steering oil
pump pulley. 49 UN30 312523

Note
• Hold the SST and power steering oil pump
drive belt by hand until the power steering oil
pump drive belt is properly seated.

(3) Turn the crankshaft clockwise to install the

power steering oil pump drive belt.
ac9uuw00001876
Note
• Verify that the power steering oil pump drive
belt is firmly attached to the pulleys.

4. Install the generator and A/C drive belt. (See 01-

10-4 Generator and A/C drive belt.)
5. Verify that the drive belt auto tensioner indicator
mark does not exceeds the maximum belt length.
(See 01-10-4 DRIVE BELT INSPECTION [MZI-
3.5].)
• If it exceeds the maximum belt length, replace
the generator and A/C drive belt.
End Of Sie
WM: DRIVE BELT AUTO TENSIONER ac9uuw00001877

01-10–6
1890-1U-06H(01-10).fm 7 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
DRIVE BELT AUTO TENSIONER INSPECTION [MZI-3.5]
id0110c1801700
1. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the front wheel and tire (RH). (See 02-10-1 GENERAL PROCEDURES (SUSPENSION).)
3. Remove the splash shield (RH).
4. Remove the generator and A/C drive belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-3.5].)
5. Verify that the drive belt auto tensioner moves
smoothly in the operational direction. BREAKER
• Replace the drive belt auto tensioner if BAR
01-10
necessary.

Tightening torque
8.9—12.1 N·m {91—123 kgf·cm, 79—107
DRIVE BELT
in·lbf} AUTO
TENSIONER

ac9uuw00000199

6. Turn the drive belt auto tensioner pulley by hand

and verify that it rotates smoothly.
• Replace the drive belt auto tensioner if
necessary.

Tightening torque
8.9—12.1 N·m {91—123 kgf·cm, 79—107 DRIVE BELT
in·lbf} AUTO
TENSIONER
PULLEY
7. Install in the reverse order of removal.
End Of Sie
WM: ENGINE COMPLETE

ac9uuw00000200

VALVE CLEARANCE INSPECTION/ADJUSTMENT [MZI-3.5]

id0110c1800200
Valve Clearance Inspection
1. Disconnect the negative battery cable.
2. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the ventilation hose.
4. Remove the resonance chamber. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove the dynamic chamber and throttle body as a single unit. (See 01-13-4 INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [MZI-3.5].)
6. Disconnect the wiring harness.
7. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5].)
8. Remove the dipstick.
9. Remove the cylinder head cover. (See 01-10-11 TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.5].)
10. Remove the front wheel and tire (RH). (See 02-10-1 GENERAL PROCEDURES (SUSPENSION).)
11. Remove the splash shield (RH).

01-10–7
1890-1U-06H(01-10).fm 8 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
12. Measure the valve clearance.
(1) Rotate the crankshaft clockwise and verify
TIMING MARK
that the timing mark of the intake side APPROX. 6 ° APPROX. 6 °
camshaft sprocket is in the position shown in
the figure. In this position, the No.1 cylinder is
at the TDC of the compression stroke.

ac9uuw00001886

(2) Measure the valve clearance of location A

shown in the figure. ENGINE FRONT SIDE
• If it is not within the specification, replace
the tappet and adjust the valve clearance
to the median value of the standard. LH RH
EX IN IN EX
Standard valve clearance [Engine cold]
IN: 0.150—0.250 mm {0.00591—0.00984 in}
EX: 0.300—0.400 mm {0.0119—0.0157 in}

Note A A
• Make sure to note down the measured A B
values for choosing the suitable replacement
tappets. B A
B B

A B
B A

ac9uuw00000209

(3) Mark the crank pulley and engine front cover

as shown in the figure.
(4) Rotate the crankshaft clockwise 360 ° so that
the No.5 cylinder is at TDC of the
compression stroke.
(5) Measure the valve clearance of location B
shown in the figure.
• If it is not within the specification, replace
the tappet and adjust the valve clearance
to the median value of the standard.

Standard valve clearance [Engine cold]

ac9uuw00001887
IN: 0.150—0.250 mm {0.00591—0.00984 in}
EX: 0.300—0.400 mm {0.0119—0.0157 in}

Note
• Make sure to note down the measured values for choosing the suitable replacement tappets.

13. Install in the reverse order of removal.

01-10–8
1890-1U-06H(01-10).fm 9 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Valve Clearance Adjustment
1. Follow the cylinder head gasket replacement procedure and remove the camshafts and camshaft sprocket as a
single unit. (See 01-10-23 CYLINDER HEAD GASKET REPLACEMENT [MZI-3.5].)
2. Remove the tappet.
3. Install an appropriate tappet based on the results of the valve clearance inspection.
Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance

Standard valve clearance [Engine cold] 01-10

IN: 0.150—0.250 mm {0.00591—0.00984 in}
EX: 0.300—0.400 mm {0.0119—0.0157 in}

4. Install in the reverse order of removal.

End Of Sie
COMPRESSION INSPECTION [MZI-3.5]
id0110c1800300

Warning
• Hot engines and oil can cause severe burns. Turn off the engine and wait until they are cool.
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)

1. Verify that the battery is fully charged.

• Recharge it if necessary. (See 01-17-2 BATTERY INSPECTION [MZI-3.5].)
2. Warm up the engine to the normal operating temperature.
3. Perform “Fuel Line Safety Procedure”. Leave the fuel pump relay removed. (See 01-14-5 BEFORE REPAIR
PROCEDURE [MZI-3.5].)
4. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove the dynamic chamber and throttle body as a single unit. (See 01-13-4 INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [MZI-3.5].)
6. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5].)
7. Remove the spark plugs.
8. Measure the compression pressure using the following procedure.
(1) Connect the compression gauge into the
spark plug hole.
(2) Crank the engine a minimum of five
compression strokes and record the highest
reading.

Note
• Note the approximate number of
compression strokes required to obtain the
highest reading.

(3) Repeat the test on each cylinder, cranking the

ac9uuw00000138
engine approximately the same number of
compression strokes.
(4) The indicated compression pressures are considered within specification if the lowest reading cylinder is
within 75 % of the highest reading. Refer to the compression pressure limit chart.
• If the compression in one or more cylinders is low or the compression difference between cylinders
exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the
compression.
— If the compression increases, the piston, the piston rings, or cylinder wall may be worn and
overhaul is required.
— If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
— If two adjacent cylinders indicate low compression pressures, and squirting oil on the piston does
not increase compression, the head gasket may be leaking between cylinders. Engine oil and/or
coolant in the cylinders could result from this condition.

01-10–9
1890-1U-06H(01-10).fm 10 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Compression Pressure Limit Chart
kPa {kgf/cm2, psi}
Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
pressure pressure pressure pressure pressure pressure pressure pressure
924 696 1,131 848 1,338 1,000 1,544 1,158
{9.41, 134} {7.10, 101} {11.52, 164} {8.65, 123} {13.63, 194} {10.20, 146} {15.73, 224} {11.81, 168}
938 703 1,145 855 1,351 1,014 1,558 1,165
{9.56, 136} {7.17, 102} {11.67, 166} {8.72, 124} {13.77, 196} {10.34, 147} {15.88, 226} {11.88, 169}
952 717 1,158 869 1,365 1,020 1,572 1,179
{9.70, 138} {7.31, 104} {11.80, 168} {8.86, 126} {13.91, 198} {10.40, 148} {16.02, 228} {12.02, 171}
965 724 1,172 876 1,379 1,034 1,586 1,186
{9.83, 140} {7.38, 106} {11.94, 170} {8.93, 127} {14.05, 200} {10.54, 150} {16.16, 230} {12.09, 172}
979 738 1,186 889 1,303 1,041 1,600 1,200
{9.97, 142} {7.53, 107} {12.08, 172} {9.07, 129} {13.28, 202} {10.62, 151} {16.30, 232} {12.24, 174}
933 745 1,200 903 1,407 1,055 1,055 1,207
{9.51, 144} {7.60, 109} {12.23, 174} {9.21, 131} {14.34, 204} {10.76, 153} {10.75, 153} {12.31, 175}
1,007 758 1,214 910 1,420 1,062 1,627 1,220
{10.26, 146} {7.73, 110} {12.37, 176} {9.28, 132} {14.47, 206} {10.83, 154} {16.58, 154} {12.44, 177}
1,020 765 1,227 917 1,434 1,075 1,641 1,227
{10.39, 148} {7.80, 111} {12.50, 178} {9.35, 133} {14.61, 208} {10.96, 156} {16.72, 238} {12.51, 178}
1,034 779 1,241 931 1,448 1,083 1,655 1,241
{10.54, 150} {7.94, 113} {12.65, 180} {9.49, 135} {14.76, 210} {10.04, 157} {16.87, 240} {12.65, 180}
1,048 786 1,255 936 1,462 1,089 1,669 1,248
{10.68, 152} {8.02, 114} {12.79, 182} {9.54, 136} {14.90, 212} {11.10, 158} {17.01, 242} {12.73, 181}
1,062 793 1,269 952 1,476 1,103 1,682 1,262
{10.82, 154} {8.09, 115} {12.93, 184} {9.70, 138} {15.04, 214} {11.25, 160} {17.14, 244} {12.87, 183}
1,076 807 1,282 965 1,489 1,117 1,696 1,269
{10.96, 156} {8.23, 117,} {13.06, 186} {9.84, 140} {15.17, 216} {11.39, 162} {17.28, 246} {12.94, 184}
1,089 814 1,296 972 1,503 1,124 1,710 1,202
{11.10, 158} {8.30, 118} {13.21, 188} {9.91, 141} {15.32, 218} {11.46, 163} {17.43, 248} {12.26, 186}
1,103 827 1,310 979 1,517 1,138 1,724 1,289
{11.24, 160} {8.43, 120} {13.35, 190} {9.98, 142} {15.46, 220} {11.60, 165} {17.57, 250} {13.14, 187}
1,110 834 1,324 993 1,631 1,145
— —
{11.31, 161} {8.50, 121} {13.49, 192} {10.2, 144} {16.62, 222} {11.67, 166}

9. Remove the compression gauge.

10. Install the spark plugs. (See 01-18-3 SPARK PLUG REMOVAL/INSTALLATION [MZI-3.5].)
11. Install the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5].)
12. Install the dynamic chamber and throttle body as a single unit. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
13. Install the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
14. Install the fuel pump relay.
15. Complete the “AFTER REPAIR PROCEDURE”. (See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)
End Of Sie
WM: TIMING CHAIN

01-10–10
1890-1U-06H(01-10).fm 11 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.5]
id0110c1801000

Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].) 01-10
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

Note
• The following procedure “TIMING CHAIN EMOVAL/INSTALLATION” is performed after the engine and
transaxle component is removed from the vehicle. (See 01-10-41 ENGINE REMOVAL/INSTALLATION
[MZI-3.5].)

1. Drain the engine oil. (See 01-11-2 ENGINE OIL REPLACEMENT [MZI-3.5].)
2. Remove the engine and transaxle component. (See 01-10-41 ENGINE REMOVAL/INSTALLATION [MZI-3.5].)
3. Secure the engine and transaxle component
using a hoist and the SST.
4. Remove the dynamic chamber and throttle body
as a single unit. (See 01-13-4 INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION [MZI-3.5].) 49 L017 5A0
5. Remove the ignition coils. (See 01-18-2
IGNITION COIL REMOVAL/INSTALLATION [MZI-
3.5].)
6. Remove the dipstick.
7. Remove the power steering oil pump drive belt.
(See 01-10-4 DRIVE BELT REMOVAL/
INSTALLATION [MZI-3.5].)
8. Remove the power steering oil pump. (See 06-14-
20 POWER STEERING OIL PUMP REMOVAL/
INSTALLATION.)
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Start the engine and:
(1) Inspect the runout and contact on the pulley
and belt.
(2) Inspect for engine oil, engine coolant, ATF,
power steering fluid and fuel leakage.
(3) Verify the ignition timing, idle speed and idle
mixture. (See 01-10-57 ENGINE TUNE-UP ac9uuw00001882
[MZI-3.5].)
(4) Engine accessories operation.
12. Perform a road test.

01-10–11
1890-1U-06H(01-10).fm 12 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]

8.5—11.5 N·m
10 N·m {102 kgf·cm, 89 in·lbf} SST {87—117 kgf·cm, 5.2—7.2 N·m
8.9—12.1 N·m
+ 20—28 {2.1—2.8, 15—20} 76—101 in·lbf} {54—73 kgf·cm,
{91—123 kgf·cm, 8
79—107 in·lbf} 47—63 in·lbf}
10 SEALANT

15 {1.5, 11}
+ 63.7—86.3
5
{6.50—8.80, R
47.0—63.6}
6
8.5—11.5 N·m R
{87—117 kgf·cm,
76—101 in·lbf} 12 8.5—11.5 N·m
R {87—117 kgf·cm,
SEALANT

1
76—101 in·lbf} 7
SST
R
9
4 R SST OIL
8.5—11.5 N·m
{87—117 kgf·cm,
3 SST OIL
76—101 in·lbf} SEALANT
2 R 13

120 {12.2, 88.5}

- 360 °
+ 47—53 {4.8—5.4, 35—39}
+ (85 °—95 °)
R
11
14
8.5—11.5 N·m
{87—117 kgf·cm, 8.5—11.5 N·m
76—101 in·lbf} {87—117 kgf·cm,
76—101 in·lbf}

N·m {kgf·m, ft·lbf}

ac9uuw00000282

1 Drive belt auto tensioner 8 Cylinder head cover oil seal (RH)
2 Crankshaft pulley lock bolt (See 01-10-14 Cylinder Head Cover Oil Seal
(See 01-10-13 Crankshaft Pulley Lock Bolt Removal Removal Note.)
Note.) (See 01-10-20 Cylinder Head Cover Oil Seal
(See 01-10-23 Crankshaft Pulley Lock Bolt Installation Note.)
Installation Note.) 9 No.3 engine mount bracket
3 Crankshaft pulley (See 01-10-15 Engine Front Cover and No.3 Engine
(See 01-10-13 Crankshaft Pulley Removal Note.) Mount Bracket Removal Note.)
(See 01-10-22 Crankshaft Pulley Installation Note.) (See 01-10-19 Engine Front Cover and No.3 Engine
Mount Bracket Installation Note.)
4 Front oil seal
(See 01-10-13 Front Oil Seal Removal Note.) 10 Engine front cover
(See 01-10-22 Front Oil Seal Installation Note.) (See 01-10-15 Engine Front Cover and No.3 Engine
Mount Bracket Removal Note.)
5 Cylinder head cover (LH) (See 01-10-19 Engine Front Cover and No.3 Engine
(See 01-10-14 Cylinder Head Cover Removal Note.) Mount Bracket Installation Note.)
(See 01-10-21 Cylinder Head Cover Installation
Note.) 11 OCV component (LH)
(See 01-10-15 OCV Component Removal Note.)
6 Cylinder head cover (RH) (See 01-10-17 OCV Component Installation Note.)
(See 01-10-14 Cylinder Head Cover Removal Note.)
(See 01-10-21 Cylinder Head Cover Installation 12 OCV component (RH)
Note.) (See 01-10-15 OCV Component Removal Note.)
(See 01-10-17 OCV Component Installation Note.)
7 Cylinder head cover oil seal (LH)
(See 01-10-14 Cylinder Head Cover Oil Seal 13 Chain tensioner
Removal Note.) 14 Timing chain component
(See 01-10-20 Cylinder Head Cover Oil Seal (See 01-10-16 Timing Chain Component Removal
Installation Note.) Note.)
(See 01-10-17 Timing Chain Component Installation
Note.)

01-10–12
1890-1U-06H(01-10).fm 13 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Crankshaft Pulley Lock Bolt Removal Note
1. Remove the starter. (See 01-19-2 STARTER REMOVAL/INSTALLATION [MZI-3.5].)
2. Set a flathead screwdriver to the drive plate in the
position indicated in the figure to lock the
crankshaft rotation.
3. Remove the crankshaft pulley lock bolt and
TRANSAXLE
washer.
01-10

ac9uuw00000407

Crankshaft Pulley Removal Note

1. Remove the washer from the crankshaft pulley
lock bolt, install a suitable spacer (thickness:
approx. 14 mm {0.55 in}, diameter: approx. 30 SPACER
mm {1.18 in}), (similar to front shock absorber
lower nut) to the crankshaft pulley lock bolt, and
install the crankshaft pulley lock bolt to the
crankshaft.

CRANKSHAFT
PULLEY LOCK
BOLT
ac9uuw00002127

2. Remove the crankshaft pulley using the SST.

3. Remove the crankshaft pulley lock bolt and 303-D121
spacer. (49 UN30 3D1210)

ac9uuw00000151

Front Oil Seal Removal Note

1. Remove the front oil seal using a flathead
screwdriver as shown.

FRONT
OIL SEAL

RAG

ac9uuw00000258

01-10–13
1890-1U-06H(01-10).fm 14 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Cylinder Head Cover Removal Note
1. Remove the cylinder head cover bolts in the order shown.
RH
ENGINE FRONT SIDE
9 11 7
1
3
5

2
4 8 6
10
ac9uuw00000144

LH
ENGINE FRONT SIDE
4 10 8 6
2

5 1
11 7
9
ac9uuw00000143

Cylinder Head Cover Oil Seal Removal Note

Note
• Inspect the OCV attachment hole seals and spark plug tube attachment hole seals. Remove the any
damaged seals.
• The OCV attachment hole seals removal is shown, the spark plug tube attachment hole seals removal
procedure is the same.

1. Tap the OCV attachment hole seals and spark

plug tube attachment hole seals using the SSTs
and hammer. 49 G033 102
CYLINDER HEAD
COVER
49 G033 105

ac9uuw00000598

01-10–14
1890-1U-06H(01-10).fm 15 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Engine Front Cover and No.3 Engine Mount Bracket Removal Note
1. Loosen the engine front cover and No.3 engine
20
mount bracket installation bolts in the order 2 21
shown in the figure.

7 1
18
17 8 01-10
24 3 4
25
13
14
15
19 16
11
12
9 10
6
5
22 23
ac9uuw00001105

2. Install 4 of the engine front cover bolts (finger

tightened) into the 4 threaded holes in the engine
front cover.
(1) Tighten the bolts one turn at a time in a criss-
cross pattern until the engine front cover-to-
cylinder block seal is released.
(2) Remove the engine front cover.

ac9uuw00001106

OCV Component Removal Note

1. Loosen the OCV component installation bolts in the order shown in the figure.
RH

3
ac9uuw00002419

LH
3

1
ac9uuw00002420

01-10–15
1890-1U-06H(01-10).fm 16 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Timing Chain Component Removal Note

Caution
• Do not rotate the crankshaft counterclockwise. The timing chains may bind, causing engine
damage.

1. Turn the crankshaft clockwise so that the

crankshaft keyway is in the 11 o’clock position.
(This will position the No.1 cylinder at TDC.) ,
KEYWAY 11 O CLOCK

Note
• Verify that there are timing marks in three
locations (Yellow 1, Black 2) on the timing
chain. If any timing marks are missing, mark
the timing chain.
• When marking the crankshaft sprocket side
timing chain, change the mark color.
• When the timing chain is replaced with a
ac9uuw00000210
new one, mark the new timing chain at the
same positions as the removed timing chain.

2. Mark the timing chain at the position of each

timing sprocket timing mark.
TIMING
TIMING
MARK
MARK

TIMING
MARK
ac9uuw00000153

3. Remove the timing chain in the following order.

2
(1) Chain tensioner
(2) Timing chain
(3) Tensioner arm
(4) Chain guide
(5) Crankshaft sprocket

3
4

5
ac9uuw00000154

01-10–16
1890-1U-06H(01-10).fm 17 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
OCV Component Installation Note
1. Tighten the OCV component installation bolts in the order shown in the figure.
RH

01-10
3

1
ac9uuw00002417

LH
1

3
ac9uuw00002418

Timing Chain Component Installation Note

1. Verify that the crankshaft keyway is at 11 o’clock
position.
,
O CLOCK
Note
• Of the three marked locations on the timing
chain, align the mark that has a different
color to the crankshaft sprocket side timing
mark.

ac9uuw00000284

2. Place alignment marks on the timing chain

corresponding to each of the alignment marks on
the timing sprocket. TIMING
TIMING MARK
MARK

TIMING
MARK
ac9uuw00000153

01-10–17
1890-1U-06H(01-10).fm 18 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
3. Push down the link plate of the timing chain
tensioner and release the plunger lock.

Note
• The plunger should retract with minimal
force. If binding occurs, remove the chain
tensioner from the vise and reset it in the
vise.
PLUNGER

LINK PLATE

ac9uuw00000166

4. Secure the chain tensioner using a vice attached

with a soft base, and slowly press the plunger
back shown in the figure while pressing down the
link plate.
5. Release the pressure slightly from the plunger,
and move the plunger back and forth 2—3 mm
{0.08—0.11 in).

LINK PLATE

ac9uuw00000167

6. Insert an approx. 1.5 mm {0.059 in} thick wire or

paper clip where the link plate hole and the
tensioner body hole overlap to fix the link plate
and lock the plunger.

ac9uuw00000156

7. Install the timing chain in the following order.

4
(1) Crankshaft sprocket
(2) Chain guide
(3) Tensioner arm
(4) Timing chain
(5) Chain tensioner

Tightening torque
8.5—11.5 N·m {87—117 kgf·cm, 76—101 3
in·lbf} 2

ac9uuw00000155

01-10–18
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MECHANICAL [MZI-3.5]
8. Remove the retaining wire.

WIRE

01-10

ac9uuw00000159

Engine Front Cover and No.3 Engine Mount Bracket Installation Note
1. Apply the silicon sealant (Loctite 5900) to the
engine front cover shown in the figure.

Silicon sealant thickness A

A: 5.0—6.0 mm {0.197—0.236 in}
B: 2.5—3.5 mm {0.099—0.137 in}

B B
A A
B B
B
B
B B

A
A

ac9uuw00000599

2. Install the engine front cover and No.3 engine

mount bracket. 6
5
(1) Tighten the engine front cover and No.3
engine mount bracket installation bolts in 4
steps in the order shown in the figure.
8 9
Caution
• Install the engine front cover and No.3 2
1
engine mount bracket installation bolts 7
within 10 min of applying the silicone
sealant.

Tightening torque
Installation
Step Tightening torque
position
1 1—6 10 N·m {102 kgf·cm, 89 in·lbf}
2 7—9 15 N·m {1.5 kgf·m, 11 ft·lbf} 4 3
20—28 N·m {2.1—2.8 kgf·m, ac9uuw00001107
3 1—6
15—20 ft·lbf}
63.7—86.3 N·m {6.50—8.80
4 7—9
kgf·m, 47.0—63.6 ft·lbf}

01-10–19
1890-1U-06H(01-10).fm 20 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
(2) Tighten the engine front cover installation
bolts in the order in 2 steps in the order shown 15
in the figure.

Caution 10 16
• Install the engine front cover installation
bolts within 60 min of applying the 9
14 13
silicone sealant.
4
3
Tightening torque 2
1. Tighten to 10 N·m {102 kgf·cm, 89 in·lbf}. 1
2. Tighten to 20—28 N·m {2.1—2.8 kgf·m,
15—20 ft·lbf}. 6
5
8 7
11
12
ac9uuw00001108

Cylinder Head Cover Oil Seal Installation Note

Note
• Installation of new seals is only required if damaged seals were removed during disassembly of the
engine.

1. Push the OCV attachment hole seals and spark plug tube attachment hole seals slightly in by hand.
2. Tap the OCV attachment hole seals and spark
plug tube attachment hole seals using the SST
and hammer.
CYLINDER HEAD 49 W026 001
COVER

ac9uuw00000602

01-10–20
1890-1U-06H(01-10).fm 21 ページ ２００６年１２月２０日　水曜日　午後１２時０分

MECHANICAL [MZI-3.5]
Cylinder Head Cover Installation Note
1. Apply silicone sealant (Loctite 5900) to the mating faces as shown.
RH
ENGINE 8 mm {0.31 in}
SEALANT
FRONT SIDE

01-10

SEALANT

8 mm {0.31 in}
ac9uuw00000212

LH
ENGINE 8 mm {0.31 in}
FRONT SIDE SEALANT

SEALANT
8 mm {0.31 in}
ac9uuw00000213

2. Install the cylinder head cover with a new gasket.

3. Tighten the bolts in the order as shown.

Caution
• Install the cylinder head cover installation bolt and studs within 5 min of applying the silicone
sealant.

RH
ENGINE FRONT SIDE
3 1 5
11
9
7

10
8 2 4 6
ac9uuw00000164

LH
ENGINE FRONT SIDE
Tightening torque 2 4 6
8
8.5—11.5 N·m {87—117 kgf·cm, 76—101 10
in·lbf}

7 11
3 1 5
ac9uuw00000165

01-10–21
1890-1U-06H(01-10).fm 22 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Front Oil Seal Installation Note

Note
• Apply clean engine oil to the front oil seal bore in the engine front cover.

1. Push the front oil seal slightly in by hand.

2. Tap the front oil seal in evenly using the SST and
a hammer.
Substitution SST
• 49 G028 203
Outer diameter: 58—70 mm {2.3—2.7 in} 49 G028 203
Inner diameter: 56—58 mm {2.3—2.2 in}
Tube with board thickness 2 mm {0.079 in} or
more

ac9uuw00000600

Crankshaft Pulley Installation Note

Note
• Lubricate the contact surface (exterior area of inner diameter) of the front oil seal with clean engine oil.

1. Install the crankshaft pulley, washer, and SST to

CRANKSHAFT PULLEY
the crankshaft. ENGINE FRONT
COVER
303-102
(49 UN01 002)

WASHER
CRANKSHAFT

ac9uuw00001884

2. Tighten the SST nut and install the crankshaft

pulley.
303-102
(49 UN01 002)
WASHER

ac9uuw00002114

01-10–22
1890-1U-06H(01-10).fm 23 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Crankshaft Pulley Lock Bolt Installation Note
1. Set a flathead screwdriver to the drive plate in the position indicated in the figure to lock the crankshaft rotation.
2. Tighten the new crankshaft pulley lock bolt in four
steps.
(1) Tighten to 120 N·m {12.2 kgf·m, 88.5 ft·lbf}.
(2) Loosen 360 ° (one full turn) in reverse order.
(3) Tighten to 47—53 N·m {4.8—5.4 kgf·m, 35— TRANSAXLE
39 ft·lbf}. 01-10
(4) Tighten 85 °—95 °.
3. Install the starter. (See 01-19-2 STARTER
REMOVAL/INSTALLATION [MZI-3.5].)
End Of Sie
WM: CYLINDER HEAD GASKET

ac9uuw00000406

CYLINDER HEAD GASKET REPLACEMENT [MZI-3.5]

id0110c1800700

Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

Note
• The following procedure “CYLINDER HEAD GASKET REPLACEMENT” is performed after the engine and
transaxle component is removed from the vehicle. (See 01-10-41 ENGINE REMOVAL/INSTALLATION
[MZI-3.5].)

1. Drain the engine oil. (See 01-11-2 ENGINE OIL REPLACEMENT [MZI-3.5].)
2. Remove the engine and transaxle component. (See 01-10-41 ENGINE REMOVAL/INSTALLATION [MZI-3.5].)
3. Using a hoist, lower the engine and transaxle component on a level surface.

Warning
• Protect and stabilize the lowered engine and transaxle component with crossties to prevent injury
or damage due to roll over.

4. Remove the dynamic chamber and throttle body as a single unit. (See 01-13-4 INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove the fuel injector and fuel distributor together as a single unit. (See 01-14-23 FUEL INJECTOR
REMOVAL/INSTALLATION [MZI-3.5].)
6. Remove the thermostat and thermostat housing together as a single unit. (See 01-12-10 THERMOSTAT
REMOVAL/INSTALLATION [MZI-3.5].)
7. Remove the Intake manifold. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
8. Remove both WU-TWCs together with both exhaust manifolds as a single unit. (See 01-15-1 EXHAUST
SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
9. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5].)
10. Remove the dipstick.
11. Remove the power steering oil pump drive belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-
3.5].)
12. Remove the power steering oil pump. (See 06-14-20 POWER STEERING OIL PUMP REMOVAL/
INSTALLATION.)
13. Remove the generator. (See 01-17-4 GENERATOR REMOVAL/INSTALLATION [MZI-3.5].)

Caution
• When removing the timing chain and marking the timing marks on the chain, mark the camshaft
timing chain as well.

14. Follow the “TIMING CHAIN REMOVAL/INSTALLATION” procedure and removal the timing chain. (See 01-10-
11 TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.5].)
15. Remove in the order indicated in the table.
16. Install in the reverse order of removal.

01-10–23
1890-1U-06H(01-10).fm 24 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
17. Start the engine and:
(1) Inspect the runout and contact on the pulley and belt.
(2) Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage.
(3) Verify the ignition timing, idle speed and idle mixture. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
(4) Engine accessories operation
18. Perform a road test. .

8.5—11.5 N·m
{87—117 kgf·cm,
76—101 in·lbf}

1
8.5—11.5 N·m
8.5—11.5 N·m {87—117 kgf·cm,
{87—117 kgf·cm, 8.5—11.5 N·m
76—101 in·lbf}
76—101 in·lbf} {87—117 kgf·cm,
76—101 in·lbf}
3 2 4

5 8

7 R R
20 {2.0, 15} 20 {2.0, 15}
+ 35 {3.6, 26} SEALANT + 35 {3.6, 26}
+ 90 ° + 90 °
+ 90 ° + 90 °
SEALANT
+ 90 ° + 90 °
6 9

11
8.5—11.5 N·m
{87—117 kgf·cm,
76—101 in·lbf}

R 12 10 R

N·m {kgf·m, ft·lbf}

ac9uuw00000214

1 Camshaft cap (LH) 8 Camshaft component (RH)

2 Camshaft timing chain tensioner (LH) (See 01-10-25 Camshaft Component Removal
Note.)
3 Camshaft timing chain (LH) (See 01-10-29 Camshaft Component Installation
4 Camshaft component (LH) Note.)
(See 01-10-25 Camshaft Component Removal 9 Cylinder head (LH)
Note.) (See 01-10-28 Cylinder Head Removal Note.)
(See 01-10-29 Camshaft Component Installation (See 01-10-29 Cylinder Head Installation Note.)
Note.)
10 Cylinder head gasket (LH)
5 Camshaft cap (RH)
11 Cylinder head (RH)
6 Camshaft timing chain tensioner (RH) (See 01-10-28 Cylinder Head Removal Note.)
7 Camshaft timing chain (RH) (See 01-10-29 Cylinder Head Installation Note.)
12 Cylinder head gasket (RH)

01-10–24
1890-1U-06H(01-10).fm 25 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Camshaft Component Removal Note
Caution
• Do not rotate the crankshaft counterclockwise. The timing chains may bind, causing engine
damage.
1. Turn the crankshaft clockwise so that the
crankshaft keyway is in the 11 o’clock position.
(This will position the No.1 cylinder at TDC.) ,
01-10
KEYWAY 11 O CLOCK
Note
• Verify that there are timing marks in three
locations (Yellow 1, Black 2) on the timing
chain. If any timing marks are missing, mark
the timing chain.
• When marking the crankshaft sprocket side
timing chain, change the mark color.
• When the timing chain is replaced with a
new one, mark the new timing chain at the ac9uuw00001160
same positions as the removed timing chain.
2. Mark the timing chain at the position of each
timing sprocket timing mark.
TIMING
TIMING
MARK
Note MARK
• Verify that there are timing marks in two
locations on the camshaft timing chain. If
any timing marks are missing, mark the
camshaft timing chain.
• If replacing with a new camshaft timing
chain, place alignment marks in the same
positions as those prior to the replacement.

TIMING
MARK
ac9uuw00000153
3. Mark the camshaft timing chain at the positions where it is aligned with each of the camshaft sprocket on both
banks.
LH
TIMING MARK

BACK VIEW TIMING MARK

ac9uuw00000991

01-10–25
1890-1U-06H(01-10).fm 26 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
RH
TIMING MARK

BACK VIEW
TIMING MARK

ac9uuw00000992

4. Remove the timing chain in the following order.

2
(1) Chain tensioner
(2) Timing chain
(3) Tensioner arm
(4) Chain guide
(5) Crankshaft sprocket

3
4

5
ac9uuw00000154

5. Rotate the crankshaft counterclockwise until the

keyway is in the 9 o'clock position.
6. Slowly compress the camshaft timing chain ,
KEYWAY 9 O CLOCK
tensioner (LH) piston by hand.

ac9uuw00000300

01-10–26
1890-1U-06H(01-10).fm 27 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
7. Insert an approx. 1.0 mm {0.039 in} thin wire or
paper clip into the camshaft timing chain
tensioner (LH) shown in the figure to hold the WIRE
tensioner piston.

Note
• When the timing chain removed, valve
spring pressure will rotate the camshaft (LH) 01-10
approx. 3 ° to a neutral position.

ac9uuw00000969

8. Verify that the camshafts (LH) are in the neutral TIMING MARK
position.
TIMING MARK
Note
• The cylinder head and the camshaft bearing
caps are numbered to make sure they are
reassembled in their original position. When
removed, keep the bearing caps with the
cylinder head they were removed from. Do
not mix the caps.

ac9uuw00000613

9. Loosen the LH bank camshaft cap bolts in several

ENGINE FRONT SIDE 14 13 12 11 10 9
passes in the order shown in the figure and
remove the camshaft cap.
10. Remove the camshaft, camshaft sprocket,
camshaft timing chain, and camshaft timing chain 15
tensioner of the LH bank as a single unit. 16
11. Slowly compress the camshaft timing chain
tensioner (RH) piston by hand. 8
7

6 5 4 3 2 1
ac9uuw00000171

12. Insert an approx. 1.0 mm {0.039 in} thin wire or

paper clip into the camshaft timing chain
WIRE
tensioner (RH) shown in the figure to hold the
tensioner piston.

ac9uuw00000970

01-10–27
1890-1U-06H(01-10).fm 28 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
13. Put a wrench to the position shown in the figure
on the RH bank camshaft, rotate the RH bank
camshaft counterclockwise, and set the camshaft
to the neutral position.

ac9uuw00000288

Note TIMING MARK

• The cylinder head and the camshaft bearing
caps are numbered to make sure they are
reassembled in their original position. When
removed, keep the bearing caps with the
cylinder head they were removed from. Do
not mix the caps.
TIMING MARK

ac9uuw00000614

14. Loosen the RH bank camshaft cap bolts in ENGINE FRONT SIDE
several passes in the order shown in the figure 6 5 4 3 2 1
and remove the camshaft cap.
15. Remove the camshaft, camshaft sprocket, 7
camshaft timing chain, and camshaft timing chain 8
tensioner of the RH bank as a single unit.
16
15

14 13 12 11 10 9
ac9uuw00002230

Cylinder Head Removal Note

1. Loosen the cylinder head bolts in several passes
in the order shown. ENGINE FRONT SIDE

LH RH
1 2

12 11
3 4

16 15
7 8

18 17
9 10

14 13
5 6

ac9uuw00000215

01-10–28
1890-1U-06H(01-10).fm 29 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Cylinder Head Installation Note
Note
• The cylinder head bolts must be replaced with new bolts. The bolts are torque-to-yield designed and
cannot be reused.
1. Tighten the cylinder head bolts in the order in 6
steps in the order shown in the figure. ENGINE FRONT SIDE

01-10
Tightening torque LH RH
Installation 18 17
Step Tightening torque
position
1 1—16 20 N·m {2.0 kgf·m, 15 ft·lbf}
2 1—16 35 N·m {3.6 kgf·m, 26 ft·lbf}
7 8
3 1—16 90 °
16 15
4 1—16 90 °
5 1—16 90 °
3 4
8.5—11.5 N·m {87—117 kgf·cm,
6 17, 18 12 11
76—101 in·lbf}

1 2
10 9

5 6
14 13

ac9uuw00000216

Camshaft Component Installation Note

1. Assemble the camshaft timing chain tensioners on both sides.
Tightening torque
8.5—11.5 N·m {87—117 kgf·cm, 76—101 in·lbf}
Note
• Install the camshaft, camshaft sprocket and camshaft timing chain of the both bank as a single unit.
2. Install the camshaft component (RH).
(1) Install the camshaft timing chain by aligning the colored links on the camshaft timing chain with the marks
on the camshaft sprockets (RH).
RH

TIMING MARK

BACK VIEW
TIMING MARK

ac9uuw00002024

01-10–29
1890-1U-06H(01-10).fm 30 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
(2) Position the camshaft component onto the
cylinder head (RH) in the neutral position as TIMING MARK
shown.

TIMING MARK

ac9uuw00000614

(3) Install the RH bank camshaft caps and ENGINE FRONT SIDE
temporarily tighten the camshaft cap bolts 11 12 13 14 15 16
evenly in the order shown in several passes.
10
Tightening torque 9
8.5—11.5 N·m {87—117 kgf·cm, 76—101
in·lbf} 1
2

3 4 5 6 7 8
ac9uuw00000615

(4) Remove the retaining wire inserted into the

camshaft timing chain tensioner (RH).
WIRE

ac9uuw00000971

(5) Using the RH bank camshaft sprocket

installation bolt at the position shown in the
figure, rotate the RH bank camshaft
clockwise.

ac9uuw00000616

APPROX. 6 °
TIMING MARK

APPROX. 13 °

TIMING MARK

ac9uuw00000617

01-10–30
1890-1U-06H(01-10).fm 31 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
3. Install the camshaft component (LH).
(1) Install the camshaft timing chain by aligning the colored links on the camshaft timing chain with the marks
on the camshaft sprockets (LH).
LH

TIMING MARK

01-10

BACK VIEW

TIMING MARK

ac9uuw00002025

(2) Position the camshafts onto the cylinder head TIMING MARK
(LH) in the neutral position as shown.
TIMING MARK

ac9uuw00000613

(3) Install the LH bank camshaft caps and

ENGINE FRONT SIDE 3 4 5 6 7 8
temporarily tighten the camshaft cap bolts
evenly in the order shown in several passes.

Tightening torque 2
8.5—11.5 N·m {87—117 kgf·cm, 76—101 1
in·lbf}
9
10

11 12 13 14 15 16
ac9uuw00000619

01-10–31
1890-1U-06H(01-10).fm 32 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
(4) Remove the retaining wire inserted into the
camshaft timing chain tensioner (LH).
WIRE

ac9uuw00000972

4. Turn the crankshaft clockwise so that the

crankshaft keyway is in the 11 o’clock position.
(This will position the No.1 cylinder at TDC.) ,
KEYWAY 11 O CLOCK
5. Follow the “TIMING CHAIN REMOVAL/
INSTALLATION” procedure and install the timing
chain. (See 01-10-11 TIMING CHAIN REMOVAL/
INSTALLATION [MZI-3.5].)
End Of Sie
WM: FRONT OIL SEAL

ac9uuw00001160

FRONT OIL SEAL REPLACEMENT [MZI-3.5]

id0110c1800800
1. Disconnect the negative battery cable.
2. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
3. Position the power steering reserve tank out of the way. (See 06-14-20 POWER STEERING OIL PUMP
REMOVAL/INSTALLATION.)
4. Remove the both front wheels and tires. (See 02-10-1 GENERAL PROCEDURES (SUSPENSION).)
5. Remove the splash shield (RH).
6. Position the both ABS wheel-speed sensor out of the way. (See 04-18-11 FRONT ABS WHEEL-SPEED
SENSOR REMOVAL/INSTALLATION.)
7. Position the front stabilizer control link (lower side) (RH) out of the way. (See 02-13-9 FRONT STABILIZER
REMOVAL/INSTALLATION.)
8. Position the tie-rod end ball joint (RH) out of the way. (See 02-13-11 FRONT CROSSMEMBER REMOVAL/
INSTALLATION.)
9. Remove the front shock absorber (LH) lower side bolts, position and secure the wheel hub and steering
knuckle component (LH) out of the way with a rope or wire. (See 02-13-3 FRONT SHOCK ABSORBER AND
SPRING REMOVAL/INSTALLATION.)
10. Disconnect the front drive shaft (RH) from the joint shaft side. (See 03-13-14 FRONT DRIVE SHAFT
REMOVAL/INSTALLATION.)
11. Remove the front pipe and middle pipe as a single unit. (See 01-15-1 EXHAUST SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
12. Position the propeller shaft out of the way. (AWD) (See 03-15-2 PROPELLER SHAFT REMOVAL/
INSTALLATION.)
13. Remove the generator and A/C drive belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-3.5].)
14. Remove the power steering oil pump drive belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-
3.5].)
15. Remove in the order indicated in the table.
16. Install in the reverse order of removal.

01-10–32
1890-1U-06H(01-10).fm 33 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]

74.5—104.9 {7.60—10.6, 55.0—77.3}

7.8—10.8 N·m {80—110 kgf·cm, 70—95 in·lbf}

43.1—74 {4.40—7.54, 31.8—54.5}

SST
43.1—60.7 {4.40—6.18,
2 31.8—44.7}

01-10
3
74.5—104.9
{7.60—10.6,
55.0—77.3}

SST OIL

R
4
1

5
R
120 {12.2, 88.5} -360 °+47—53 SST
{4.8—5.4, 35—39} +(85 °—95 °)
OIL

N·m {kgf·m, ft·lbf}

ac9uuw00000248

1 Crankshaft pulley lock bolt 4 Crankshaft pulley

(See 01-10-34 Crankshaft Pulley Lock Bolt Removal (See 01-10-36 Crankshaft Pulley Removal Note.)
Note.) (See 01-10-37 Crankshaft Pulley Installation Note.)
(See 01-10-39 Crankshaft Pulley Lock Bolt 5 Front oil seal
Installation Note.) (See 01-10-37 Front Oil Seal Removal Note)
2 No.3 engine mount (See 01-10-37 Front Oil Seal Installation Note)
(See 01-10-34 No.3 Engine Mount Removal Note.)
(See 01-10-38 No.3 Engine Mount Installation
Note.)
3 No.3 engine mount stay (No.3 engine mount side)

01-10–33
1890-1U-06H(01-10).fm 34 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Crankshaft Pulley Lock Bolt Removal Note
1. Remove the cover as shown in the figure.

COVER

FASTENER

ac9uuw00001612
2. Set a wrench to the drive plate bolt at the position
shown in the figure to lock the crankshaft rotation.
3. Remove the crankshaft pulley lock bolt and
washer.

FRONT

ac9uuw00000249
No.3 Engine Mount Removal Note
1. Loosen the No.1 engine mount bolt C.

FRONT C

ac9uuw00002421
2. Remove the No.1 engine mount bracket bolts A
and B as shown.
Note
• Do not remove the No.1 engine mount
rubber from the front crossmember. B

3. Position the coolant reserve tank out of the way.

(See 01-12-7 COOLANT RESERVE TANK A
REMOVAL/INSTALLATION [MZI-3.5].) FRONT
4. Remove the following parts to install the SST.
(1) The windshield wiper arm and blade. (See 09-
19-3 WINDSHIELD WIPER ARM AND
ac9uuw00001098
BLADE REMOVAL/INSTALLATION.)
(2) The cowl grille. (See 09-16-13 COWL GRILLE
REMOVAL/INSTALLATION.)
(3) The cowl panel. (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
(4) The air cleaner. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)

01-10–34
1890-1U-06H(01-10).fm 35 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
(5) The front cooler pipe installation bolt (position
FRONT COOLER PIPE
the front cooler pipe out of the way.). INSTALLATION BOLT

FRONT COOLER
PIPE 01-10

ac9uuw00002422

5. Install the SST using the following procedure.

Caution
MAIN FRAME
• Refer to the SST instruction manual for
the basic handing procedure.

Note REAR SHAFT

• When installing the SST, adjust the position
of each shaft so that they do not interfere
with the vehicle body. SIDE BAR

FRONT SHAFT

FRONT FOOT NO.1

(ADAPTER FOR FRONT SHAFT)

FRONT FOOT NO.2

(ADAPTER FOR FRONT SHAFT)
ac9uuw00000021

(1) Install the right rear shaft of the SST to the

bolt of the right shock absorber shown in the 49 C017 5A0
figure.
(2) Install the left rear shaft of the SST to the bolt
of the left shock absorber (Identical position to
the right side).
FRONT
SIDE

ac9uuw00000185

01-10–35
1890-1U-06H(01-10).fm 36 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
(3) Install the left/right front shaft of the SST with
RH
front foot No.2 to the bolt shown in the figure. 49 C017 5A0 FRONT SIDE
(4) Adjust the positions of the SST side bars so
that they are the same height (left and right)
and horizontal.
(5) Make sure each joint is securely tightened.

LH FRONT SIDE

ac9uuw00000186

6. Support the engine using the SSTs.

49 C017 5A0
7. Remove the No.3 engine mount.

49 L017 5A0

ac9uuw00001874

Crankshaft Pulley Removal Note

1. Slightly loosen the SST (49 C017 5A0) support and tilt the engine to the lower side slightly.
2. Remove the washer from the crankshaft pulley
lock bolt, install a suitable spacer (thickness:
SPACER
approx. 14 mm {0.55 in}, diameter: approx. 30
mm {1.18 in}), (similar to front shock absorber
lower nut) to the crankshaft pulley lock bolt, and
install the crankshaft pulley lock bolt to the
crankshaft.

CRANKSHAFT
PULLEY LOCK
BOLT
ac9uuw00001899

3. Remove the crankshaft pulley using the SST.

4. Remove the crankshaft pulley lock bolt and 303-D121
spacer. (49 UN30 3D1210)

ac9uuw00000151

01-10–36
1890-1U-06H(01-10).fm 37 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Front Oil Seal Removal Note
1. Remove the front oil seal using a flathead
screwdriver as shown.

FRONT
OIL SEAL
01-10

RAG

ac9uuw00000255

Front Oil Seal Installation Note

Note
• Apply clean engine oil to the front oil seal bore in the engine front cover.

1. Push the front oil seal slightly in by hand.

2. Tap the front oil seal in evenly using the SST and
a hammer.
Substitution SST
• 49 G028 203
Outer diameter: 58—70 mm {2.3—2.7 in} 49 G028 203
Inner diameter: 56—58 mm {2.3—2.2 in}
Tube with board thickness 2 mm {0.079 in} or
more

ac9uuw00000600

Crankshaft Pulley Installation Note

Note
• Lubricate the contact surface (exterior area of inner diameter) of the front oil seal with clean engine oil.

1. Install the crankshaft pulley, washer, and SST to

CRANKSHAFT PULLEY
the crankshaft. ENGINE FRONT
COVER
303-102
(49 UN01 002)

WASHER
CRANKSHAFT

ac9uuw00001884

01-10–37
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MECHANICAL [MZI-3.5]
2. Tighten the SST nut and install the crankshaft
pulley.
303-102
(49 UN01 002)
WASHER

ac9uuw00001900

No.3 Engine Mount Installation Note

1. Using the SST (49 C017 5A0), tilt up the engine until it is vertical.
2. Tighten the bolts on the No.1 engine mount
bracket in the order of A, B.

A
FRONT

ac9uuw00001098

3. Tighten the No.1 engine mount bolt C at the

specified torque.

No.1 engine mount through-bolt tightening

torque
93.1—116.6 N·m {9.50—11.8 kgf·m, 68.7—
85.9 ft·lbf}

FRONT C

ac9uuw00002421

4. Temporarily tighten the No.3 engine mount bolt

4 1
and nuts in the order shown in the figure. 5
3
2
7
6

FRONT

ac9uuw00000222

01-10–38
1890-1U-06H(01-10).fm 39 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
5. Tighten the No.3 engine mount in the order
4 1
shown in the figure. 5
Tightening Torque 3
2
Installation 7
Tightening Torque
Position 6
74.5—104.9 N·m {7.60—10.6 kgf·m, 55.0—
1, 2, 7
77.3 ft·lbf} 01-10
FRONT
43.1—74 N·m {4.40—7.54 kgf·m, 31.8—54.5
3, 4, 5, 6
ft·lbf}

6. Remove the SST (49 C017 5A0). ac9uuw00000222

7. Install the followitng parts.
(1) Install the front cooler pipe installation bolt.
FRONT COOLER PIPE
INSTALLATION BOLT
Tightening Torque
8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}

(2) The air cleaner. (See 01-13-4 INTAKE-AIR

SYSTEM REMOVAL/INSTALLATION [MZI- FRONT COOLER
3.5].) PIPE
(3) The cowl panel. (See 09-10-14 COWL PANEL
REMOVAL/INSTALLATION.)
(4) The cowl grille. (See 09-16-13 COWL GRILLE
REMOVAL/INSTALLATION.)
ac9uuw00000146
(5) Tthe windshield wiper arm and blade. (See
09-19-3 WINDSHIELD WIPER ARM AND
BLADE REMOVAL/INSTALLATION.)
8. Install the coolant reserve tank. (See 01-12-7 COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZI-
3.5].)
Crankshaft Pulley Lock Bolt Installation Note
1. Rotate the crankshaft clockwise, and set a
wrench to the drive plate bolt at the position
shown in the figure to lock the crankshaft rotation.
2. Tighten the new crankshaft pulley lock bolt in 4
steps.
(1) Tighten to 120 N·m {12.2 kgf·m, 88.5 ft·lbf}.
(2) Loosen 360 ° (one full turn) in reverse order.
(3) Tighten to 47—53 N·m {4.8—5.4 kgf·m, 35—
39 ft·lbf}.
(4) Tighten 85 °—95 °. FRONT
3. Verify the tightening torque for the drive plate
installation bolt to which the wrench has been set.
ac9uuw00000250
(See 01-12-7 COOLANT RESERVE TANK
REMOVAL/INSTALLATION [MZI-3.5].)
4. Install the cover as shown in the figure.
End Of Sie
WM: REAR OIL SEAL

COVER

FASTENER

ac9uuw00001612

01-10–39
1890-1U-06H(01-10).fm 40 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
REAR OIL SEAL REPLACEMENT [MZI-3.5]
id0110c1800900
1. Remove the automatic transaxle. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION
[AW6A-EL, AW6AX-EL].)
2. Remove the drive plate. (See 05-17-58 DRIVE PLATE REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal. .

1 CKP sensor pulse wheel

2 Rear oil seal SST
(See 01-10-40 Rear Oil Seal Removal Note.) OIL

(See 01-10-40 Rear Oil Seal Installation Note.)

R 2

1
ac9uuw00001219

Rear Oil Seal Removal Note

1. Using a flathead screwdriver, remove the rear oil
seal.
REAR OIL
SEAL

ac9uuw00000278

Rear Oil Seal Installation Note

Note
• Lubricate the rear oil seal lips and bore with clean engine oil.

1. Push the rear oil seal slightly in by hand.

2. Tap the rear oil seal in evenly using the SST and a
hammer.
Substitution SST
• 49 W011 101
Outer diameter: 105 mm {4.13 in} or more 49 W011 101
Inner diameter: 93—105 mm {3.7—4.1 in}
Tube with board thickness 2 mm {0.079 in} or
more
End Of Sie
WM: ENGINE COMPLETE

ac9uuw00000632

01-10–40
1890-1U-06H(01-10).fm 41 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
ENGINE REMOVAL/INSTALLATION [MZI-3.5]
id0110c1800400

Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].) 01-10

1. Perform “Fuel Line Safety Procedures”. Leave the fuel pump relay removed. (See 01-14-5 BEFORE REPAIR
PROCEDURE [MZI-3.5].)
2. Disconnect both battery cables.
3. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
4. Drain the power steering fluid. (See 06-14-3 POWER STEERING FLUID INSPECTION.)
5. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
6. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
7. Remove the ventilation hose. (See 01-16-15 QUICK RELEASE CONNECTOR (EMISSION SYSTEM)
REMOVAL/INSTALLATION [MZI-3.5].)
8. Disconnect the vacuum hose. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
9. Remove the air cleaner. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
10. Remove the resonance chamber. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
11. Remove the both front wheels and tires. (See 02-10-1 GENERAL PROCEDURES (SUSPENSION).)
12. Remove the splash shield (RH).
13. Remove the generator and A/C drive belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-3.5].)
14. Disconnect the front drive shaft (RH) from the joint shaft side. (See 03-13-14 FRONT DRIVE SHAFT
REMOVAL/INSTALLATION.)
15. Disconnect the front drive shaft (LH) from the transaxle side. (See 03-13-14 FRONT DRIVE SHAFT
REMOVAL/INSTALLATION.)
16. Remove the front pipe and middle pipe as a single unit. (See 01-15-1 EXHAUST SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
17. Position the propeller shaft out of the way. (AWD) (See 03-15-2 PROPELLER SHAFT REMOVAL/
INSTALLATION.)
18. Disconnect the selector cable from the transaxle side. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
19. Disconnect the heater hose. (See 07-11-15 HEATER PIPE AND HOSE COMPONENT REMOVAL/
INSTALLATION.)
20. Disconnect the power steering return hose. (See 06-14-20 POWER STEERING OIL PUMP REMOVAL/
INSTALLATION.)
21. Disconnect the radiator hose. (See 01-12-8 RADIATOR REMOVAL/INSTALLATION [MZI-3.5].)
22. Disconnect the water hose. (See 01-11-4 OIL COOLER REMOVAL/INSTALLATION [MZI-3.5].)
23. Disconnect the ATF oil cooler hose.
24. Disconnect the plastic fuel hose. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].) (See 01-14-22
QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [MZI-3.5].)
25. Disconnect the wiring harness.

Note
• Do not disconnect the engine side of this wiring harness.

26. Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so
that it is out of the way. (See 07-11-14 A/C COMPRESSOR REMOVAL/INSTALLATION.)
27. Remove the engine and transaxle component using an engine jack in the order indicated in the figure.
28. Install in the reverse order of removal.
29. Start the engine and:
(1) Inspect the runout and contact on the pulley and belt.
(2) Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage.
(3) Verify the ignition timing, idle speed and idle mixture. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
(4) Engine accessories operation
30. Perform a road test.

Note
• If the engine is overhauled and installed to the vehicle, perform the road test and verify that there is no
malfunction.

01-10–41
1890-1U-06H(01-10).fm 42 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]

7.8—10.8 N·m
{80—110 kgf·cm, 43.1—60.7 {4.40—6.18,
74.5—104.9
70—95 in·lbf} 31.8—44.7}
{7.60—10.6,
55.0—77.3}
74.5—104.9 {7.60—10.6,
2 3
55.0—77.3}

66.6—93.1 {6.80—9.49,
49.2—68.6}

43.1—74 4
{4.40—7.54, 31.8—54.5}
74.5—104.9
{7.60—10.6,
55.0—77.3}

A B

93.1—116.6
{9.50—11.8, 68.7—85.9}

93.1—116.6 {9.50—11.8,
68.7—85.9}

1
5 18.6—25.5
{1.90—2.60,
13.8—18.8}

93.1—116.6
{9.50—11.8, A
68.7—85.9}

N·m {kgf·m, ft·lbf}

ac9uuw00002135
.

1 No.1 engine mount 2 No.3 engine mount rubber

(See 01-10-43 No.1 Engine Mount Removal Note.) (See 01-10-43 No.3 Engine Mount Rubber and No.4
Engine Mount Bracket Removal Note)
(See 01-10-44 Engine Mount Installation Note.)

01-10–42
1890-1U-06H(01-10).fm 43 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
3 No.3 engine mount stay (No.3 engine mount side) 5 Engine and transaxle
4 No.4 engine mount bracket (See 01-10-44 Engine and Transaxle Removal
(See 01-10-43 No.3 Engine Mount Rubber and No.4 Note.)
Engine Mount Bracket Removal Note)
(See 01-10-44 Engine Mount Installation Note.)

01-10
No.1 Engine Mount Removal Note
1. Remove the front under cover A and front under cover B. (See 09-16-18 FRONT UNDER COVER REMOVAL/
INSTALLATION.)
2. Remove the transverse member. (See 02-13-15 TRANSVERSE MEMBER REMOVAL/INSTALLATION.)
3. Remove the intermediate shaft installation bolt, and disconnect the steering shaft. (See 06-14-6 STEERING
WHEEL AND COLUMN REMOVAL/INSTALLATION.)
4. Remove the No.1 engine mount bracket bolts A
and B as shown.

A
FRONT

ac9uuw00000966

5. Remove the No.1 engine mount, No.1 engine

mount bracket and the front crossmember as a
single unit. (See 02-13-11 FRONT
CROSSMEMBER REMOVAL/INSTALLATION.)

NO.1 ENGINE
MOUNT
ac9uuw00000889

No.3 Engine Mount Rubber and No.4 Engine Mount Bracket Removal Note
1. Secure the engine and transaxle using an engine ENGINE, TRANSAXLE
jack and attachment.

Caution
• Remove the engine and transaxle ATTACHMENT
carefully, holding it steady. If the
transaxle falls it could be damaged or
cause injury.

2. Secure the engine, transaxle, and crossmember

component using a hoist. ENGINE JACK
acxuuw00000188

01-10–43
1890-1U-06H(01-10).fm 44 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Engine and Transaxle Removal Note

Note
• When lowering the engine, slightly move it to
ENGINE
the left side of the vehicle to set the A/C A/C
compressor out of the way. COMPRESSOR

ac9uuw00000223

Engine Mount Installation Note

1. Tighten the No.3 engine mount stud bolts.

Tightening torque
15.7—23.5 N·m {1.61—2.39 kgf·m, 11.6—17.3
ft·lbf}

NO.3 ENGINE
MOUNT BRACKET
STUD BOLT

ac9uuw00000224

2. Secure the engine and the transaxle using an ENGINE, TRANSAXLE

engine jack and attachment as shown.

ATTACHMENT

ENGINE JACK
ac9uuw00000220

3. Temporarily tighten the No.3 engine mount bolts

4 1
and nuts in the order shown in the figure.

3
2

FRONT

ac9uuw00000226

01-10–44
1890-1U-06H(01-10).fm 45 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
4. Temporarily tighten the No. 4 engine mount bracket in two passes.
(1) Temporarily tighten the No.4 engine mount
bracket in the order shown in the figure until 2
3 4
the flange surface does not adhere.

FRONT 01-10
1

ac9uuw00000890

(2) Temporarily tighten the No.4 engine mount

bracket in the order shown in the figure until 2
1 3
the flange surface firmly adheres.

FRONT

ac9uuw00000233

5. Install the No.1 engine mount, No.1 engine mount

bracket and the front crossmember as a single
unit. (See 02-13-11 FRONT CROSSMEMBER
REMOVAL/INSTALLATION.)

NO.1 ENGINE
MOUNT
ac9uuw00000889

6. Tighten the bolts on the No.1 engine mounting

bracket in the order of A, B.

Tightening torque
93.1—116.6 N·m {9.50—11.8 kgf·m, 68.7— B
85.9 ft·lbf}

A
FRONT

ac9uuw00000966

01-10–45
1890-1U-06H(01-10).fm 46 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
7. Teighten the No.1 engine mount bolt C at the
specified torque.

Tightening torque
93.1—116.6 N·m {9.50—11.8 kgf·m, 68.7—
85.9 ft·lbf}

8. Install the intermediate shaft installation bolt, and

disconnect the steering shaft. (See 06-14-6 C
FRONT
STEERING WHEEL AND COLUMN REMOVAL/
INSTALLATION.)
9. Install the transverse member. (See 02-13-15
ac9uuw00000967
TRANSVERSE MEMBER REMOVAL/
INSTALLATION.)
10. Install the front under cover A and front under cover B. (See 09-16-18 FRONT UNDER COVER REMOVAL/
INSTALLATION.)
11. Temporarily tighten the No.3 engine mount bolt
and nuts in the order shown in the figure. 1

3
2

FRONT

ac9uuw00000230

12. Tighten the No.3 engine mount in the order

4 1
shown in the figure. 5
Tightening Torque 3
2
Installation 7
Tightening Torque
Position 6
74.5—104.9 N·m {7.60—10.6 kgf·m, 55.0—
1, 2, 7
77.3 ft·lbf}
FRONT
43.1—74 N·m {4.40—7.54 kgf·m, 31.8—54.5
3, 4, 5, 6
ft·lbf}

ac9uuw00000222

13. Tighten the No.4 engine mount in the order

shown in the figure. 2
1 3
Tightening Torque
Installation
Tightening Torque
Position
66.6—93.1 N·m {6.80—9.49 kgf·m, 49.2— FRONT
1, 2, 3
68.6 ft·lbf}
74.5—104.9 N·m {7.60—10.6 kgf·m, 55.0—
4
4
77.3 ft·lbf}

End Of Sie ac9uuw00000231

ENGINE DISASSEMBLY/ASSEMBLY [MZI-3.5]

id0110c1800500
1. Remove the transaxle from the engine. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION
[AW6A-EL, AW6AX-EL].)
2. Remove the drive plate. (See 05-17-58 DRIVE PLATE REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
3. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the CMP sensor. (See 01-40-18 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION
[MZI-3.5].)
5. Remove the power steering oil pump. (See 06-14-20 POWER STEERING OIL PUMP REMOVAL/
INSTALLATION.)

01-10–46
1890-1U-06H(01-10).fm 47 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
6. Remove the generator. (See 01-17-4 GENERATOR REMOVAL/INSTALLATION [MZI-3.5].)
7. Remove the fuel injector and fuel distributor. (See 01-14-23 FUEL INJECTOR REMOVAL/INSTALLATION [MZI-
3.5].)
8. Remove the intake-air system. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
9. Remove the exhaust system. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
10. Remove the thermostat case and water hose component. (See 01-12-10 THERMOSTAT REMOVAL/
INSTALLATION [MZI-3.5].)
11. Remove the CHT sensor. (See 01-40-28 CYLINDER HEAD TEMPERATURE (CHT) SENSOR REMOVAL/ 01-10
INSTALLATION [MZI-3.5].)
12. Remove the CKP sensor. (See 01-40-16 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/
INSTALLATION [MZI-3.5].)
13. Remove the oil pressure switch. (See 01-11-3 OIL PRESSURE INSPECTION [MZI-3.5].)
14. Remove the oil cooler. (See 01-11-4 OIL COOLER REMOVAL/INSTALLATION [MZI-3.5].)
15. Disassemble in the order indicated in the table.
16. Assemble in the reverse order of disassembly. .

8.5—11.5 N·m
5 {87—117 kgf·cm,
76—101 in·lbf}
8 R
6
20—28 R
{2.1—2.8, 15—20} 16.2—23.8 {1.66—2.42, 12.0—17.5}
8.5—11.5 N·m
8.5—11.5 N·m 4 {87—117 kgf·cm,
7 {87—117 kgf·cm, 76—101 in·lbf}
21.6—30.4 76—101 in·lbf}
{2.21—3.09, 16.0—22.4} 1 9

42—62 3
{4.3—6.3, 31—45}

15 {1.5, 11}
+ 63.7—86.3
{6.50—8.80, 47.0—63.6} 2

55—60 {5.7—6.1, 41—44}

R OIL

R OIL

8.5—11.5 N·m
{87—117 kgf·cm,
76—101 in·lbf}

10

N·m {kgf·m, ft·lbf}

ac9uuw00000274

1 No.3 engine mount stay (engine front cover side) 6 Dynamic chamber bracket (engine right side)
(See 01-10-48 No.3 Engine Mount Stay (Engine 7 Dynamic chamber bracket (engine back side)
Front Cover Side) Installation Note.)
8 Water inlet pipe
2 No.3 engine mount bracket (See 01-10-48 Water Inlet Pipe Installation Note.)
3 Transfer bracket (AWD) 9 KS
4 Condenser (LH) (See 01-40-26 KNOCK SENSOR (KS) REMOVAL/
5 Condenser (RH) INSTALLATION [MZI-3.5].)
10 Oil filter adapter and oil filter

01-10–47
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MECHANICAL [MZI-3.5]
No.3 Engine Mount Stay (Engine Front Cover Side) Installation Note
1. Tighten the No.3 engine mount stay (engine front
FRONT SIDE
cover side) in the order shown in the figure.

Tightening torque
21.6—30.4 N·m {2.21—3.09 kgf·m, 16.0—22.4 2
ft·lbf}

ac9uuw00000237

Water Inlet Pipe Installation Note

1. Apply clean engine coolant to the O-ring.
End Of Sie
VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [MZI-3.5]
WM: VARIABLE VALVE TIMING ACTUATOR

id0110c1801100

Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

Caution
• The variable valve timing actuator cannot be disassembled because it is a precision unit.

Note
• The following procedure “VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION” is
performed after the engine and transaxle component is removed from the vehicle. (See 01-10-41 ENGINE
REMOVAL/INSTALLATION [MZI-3.5].)

1. Drain the engine oil. (See 01-11-2 ENGINE OIL REPLACEMENT [MZI-3.5].)
2. Remove the engine and transaxle component. (See 01-10-41 ENGINE REMOVAL/INSTALLATION [MZI-3.5].)
3. Secure the engine and transaxle component
using a hoist and the SST.
4. Remove the dynamic chamber and throttle body
as a single unit. (See 01-13-4 INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION [MZI-3.5].) 49 L017 5A0
5. Remove the ignition coils. (See 01-18-2
IGNITION COIL REMOVAL/INSTALLATION [MZI-
3.5].)
6. Remove the dipstick.
7. Remove the power steering oil pump drive belt.
(See 01-10-4 DRIVE BELT REMOVAL/
INSTALLATION [MZI-3.5].)
8. Remove the power steering oil pump. (See 06-14-
20 POWER STEERING OIL PUMP REMOVAL/
INSTALLATION.)

Caution
• When removing the timing chain and
marking the timing marks on the chain,
mark the camshaft timing chain as well.

9. Follow the “TIMING CHAIN REMOVAL/

INSTALLATION” procedure and removal the
timing chain. (See 01-10-11 TIMING CHAIN ac9uuw00001883
REMOVAL/INSTALLATION [MZI-3.5].)

01-10–48
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MECHANICAL [MZI-3.5]
10. Remove in the order indicated in the table.
11. Install in the reverse order of removal.
12. Start the engine and:
(1) Inspect the runout and contact on the pulley and belt.
(2) Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage.
(3) Verify the ignition timing, idle speed and idle mixture. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
(4) Engine accessories operation.
13. Perform a road test. .
01-10
SST
1
SST
R 2
40 {4.1, 30}
-360 °
+10 N·m {102 kgf·cm,89 in·lbf}
+ 90 °

R
40 {4.1, 30}
-360 °
+10 N·m {102 kgf·cm,89 in·lbf}
+ 90 °

N·m {kgf·m, ft·lbf}

ac9uuw00000297

1 Variable valve timing actuator component (LH) 2 Variable valve timing actuator component (RH)
(See 01-10-50 Variable Valve Timing Actuator (See 01-10-50 Variable Valve Timing Actuator
Component Removal Note.) Component Removal Note.)
(See 01-10-53 Variable Valve Timing Actuator (See 01-10-53 Variable Valve Timing Actuator
Component Installation Note.) Component Installation Note.)

01-10–49
1890-1U-06H(01-10).fm 50 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Variable Valve Timing Actuator Component Removal Note

Caution
• Do not rotate the crankshaft counterclockwise. The timing chains may bind, causing engine
damage.

1. Turn the crankshaft clockwise so that the

crankshaft keyway is in the 11 o’clock position.
(This will position the No.1 cylinder at TDC.) ,
KEYWAY 11 O CLOCK

Note
• Verify that there are timing marks in three
locations (Yellow 1, Black 2) on the timing
chain. If any timing marks are missing, mark
the timing chain.
• When marking the crankshaft sprocket side
timing chain, change the mark color.
• If replacing with a new timing chain, place
ac9uuw00001159
alignment marks in the same positions as
those prior to the replacement.

2. Mark the timing chain at the position of each

timing sprocket timing mark.
TIMING
TIMING
MARK
Caution MARK
• Verify that there are timing marks in two
locations on the camshaft timing chain. If
any timing marks are missing, mark the
camshaft timing chain.
• If replacing with a new variable valve
timing actuator, place alignment marks in
the same positions as those prior to the
replacement.

TIMING
MARK
ac9uuw00000298

01-10–50
1890-1U-06H(01-10).fm 51 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
3. Mark the camshaft timing chain at the positions where it is aligned with each of the camshaft sprocket on both
banks.
LH
TIMING MARK

01-10

BACK VIEW TIMING MARK

ac9uuw00000991

RH
TIMING MARK

BACK VIEW
TIMING MARK

ac9uuw00000992

01-10–51
1890-1U-06H(01-10).fm 52 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
4. Remove the timing chain in the following order.
2
(1) Chain tensioner
(2) Timing chain
(3) Tensioner arm
(4) Chain guide
(5) Crankshaft sprocket

3
4

5
ac9uuw00000299

5. Rotate the crankshaft counterclockwise until the

keyway is in the 9 o'clock position.
6. Slowly compress the camshaft timing chain ,
KEYWAY 9 O CLOCK
tensioner (LH) piston by hand.

ac9uuw00000300

7. Insert an approx. 1.0 mm {0.039 in} thin wire or

paper clip into the camshaft timing chain
tensioner (LH) shown in the figure to hold the WIRE
tensioner piston.

ac9uuw00000977

8. Install the SST onto the camshafts (LH).

303-1248
Note (49 UN30 312480)
• The camshaft sprocket is integrated with the
variable valve timing actuator and cannot be
disassembled.

9. Remove the variable valve timing actuator,

camshaft timing chain and the exhaust camshaft
sprocket of the LH bank as a single unit.
10. Slowly compress the camshaft timing chain
tensioner (RH) piston by hand.
ac9uuw00001217

01-10–52
1890-1U-06H(01-10).fm 53 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
11. Insert an approx. 1.0 mm {0.039 in} thin wire or
paper clip into the camshaft timing chain
WIRE
tensioner (RH) shown in the figure to hold the
tensioner piston.

01-10

ac9uuw00000978

12. Install the SST onto the camshafts (RH).

303-1248
Note (49 UN30 312480)
• The camshaft sprocket is integrated with the
variable valve timing actuator and cannot be
disassembled.

13. Remove the variable valve timing actuator,

camshaft timing chain and the exhaust camshaft
sprocket of the RH bank as a single unit.

ac9uuw00001218

Variable Valve Timing Actuator Component Installation Note

1. Align the alignment marks on the camshaft timing chain and both intake and exhaust side camshaft sprockets
of both banks.
RH

TIMING MARK

BACK VIEW
TIMING MARK

ac9uuw00002026

01-10–53
1890-1U-06H(01-10).fm 54 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
LH

TIMING MARK

BACK VIEW

TIMING MARK

ac9uuw00002027
2. Install the variable valve timing actuator, camshaft timing chain and the exhaust camshaft sprocket of the RH
bank as a single unit.
3. Remove the retaining wire inserted into the
camshaft timing chain tensioner (RH).
WIRE
4. Tighten the new camshaft sprocket (RH)
installation bolts using the following 4 steps.
(1) Tighten to 40 N·m {4.1 kgf·m, 30 ft·lbf}.
(2) Loosen 360 ° (one full turn) in reverse order.
(3) Tighten to 10 N·m {102 kgf·cm, 89 in·lbf}.
(4) Tighten to 90 °
5. Install the variable valve timing actuator, camshaft
timing chain and the exhaust camshaft sprocket
of the LH bank as a single unit.
ac9uuw00000979
6. Remove the retaining wire inserted into the
camshaft timing chain tensioner (LH).
7. Tighten the new camshaft sprocket (LH) WIRE
installation bolts using the following 4 steps.
(1) Tighten to 40 N·m {4.1 kgf·m, 30 ft·lbf}.
(2) Loosen 360 ° (one full turn) in reverse order.
(3) Tighten to 10 N·m {102 kgf·cm, 89 in·lbf}.
(4) Tighten to 90 °

ac9uuw00000980
8. Rotate the crankshaft clockwise until the keyway
is in the 11 o'clock position. (This will position the
No.1 cylinder at TDC.) ,
KEYWAY 11 O CLOCK
9. Follow the “TIMING CHAIN REMOVAL/
INSTALLATION” procedure and install the timing
chain. (See 01-10-11 TIMING CHAIN REMOVAL/
INSTALLATION [MZI-3.5].)
10. Remove the SSTs installed to the camshaft
components on both banks.
End Of Sie
WM: OIL CONTROL VALVE (OCV)

ac9uuw00001159

01-10–54
1890-1U-06H(01-10).fm 55 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZI-3.5]
id0110c1801300
1. Disconnect the negative battery cable.
2. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the ventilation hose. (See 01-16-15 QUICK RELEASE CONNECTOR (EMISSION SYSTEM)
REMOVAL/INSTALLATION [MZI-3.5].)
4. Disconnect the vacuum hose. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove the resonance chamber. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
6. Remove the dynamic chamber and throttle body as a single unit. (See 01-13-4 INTAKE-AIR SYSTEM 01-10
REMOVAL/INSTALLATION [MZI-3.5].)
7. Disconnect the wiring harness.
8. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5].)
9. Remove the dipstick.
10. Remove the cylinder head cover. (See 01-10-11 TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.5].)
11. Remove the OCV.
OCV BOLT
Note
• The LH side is shown, however, the RH side
is the same.

Tightening torque
8.5—11.5 N·m {87—117 kgf·cm, 76—101
in·lbf}

12. Install in the reverse order of removal.

End Of Sie ac9uuw00000247

OIL CONTROL VALVE (OCV) INSPECTION [MZI-3.5]

id0110c1801400
Coil Resistance Inspection
1. Disconnect the negative battery cable.
2. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
3. Disconnect the OCV connector.
4. Measure the coil resistance between terminals A and B using a tester.
• If it is not within the specification, replace the OCV.

Oil control valve resistance

5—14 ohms

5. Install in the reverse order of removal.

A
B

ac9uuw00000990

01-10–55
1890-1U-06H(01-10).fm 56 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
Spool Valve Operation Inspection
1. Disconnect the negative battery cable.
2. Remove the OCV. (See 01-10-55 OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZI-3.5].)
3. Verify that the spool valve in the OCV is in the
maximum valve timing retard position as indicated VALVE TIMING RETARD
in the figure.
• If not as specified, replace the OCV.
4. Verify that the battery is fully charged.
• If not as specified, recharge the battery.

SPOOL VALVE
(MAXIMUM VALVE TIMING RETARD POSITION)

ac9uuw00000390

5. Apply battery positive voltage between the OCV

terminals and verify that the spool valve operates
and moves to the maximum valve timing advance
position.
A
B

ac9uuw00000990

• If not as specified, replace the OCV.

VALVE TIMING VALVE TIMING
Note ADVANCE RETARD
• When applying battery positive voltage
between the OCV terminals, the connection
can be either of the following:
— Positive battery cable to terminal A,
Negative battery cable to terminal B
— Positive battery cable to terminal B,
Negative battery cable to terminal A SPOOL VALVE
(MAXIMUM VALVE TIMING ADVANCE POSITION)
6. Stop applying battery positive voltage and verify
ac9uuw00000392
that the spool valve returns to the maximum valve
timing retard position.
• If not as specified, replace the OCV. (See 01-10-55 OIL CONTROL VALVE (OCV) REMOVAL/
INSTALLATION [MZI-3.5].)
7. Install in the reverse order of removal.
End Of Sie
WM: ENGINE COMPLETE

01-10–56
1890-1U-06H(01-10).fm 57 ページ ２００６年１２月１９日　火曜日　午前１０時３１分

MECHANICAL [MZI-3.5]
ENGINE TUNE-UP [MZI-3.5]
id0110c1800600

Note
• If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to
the idle speed. This is due to the fuel cut control operation, which prevents overheating, and it does not
indicate a malfunction.

Engine Tune-up Preparation 01-10

1. Verify that the selector lever is in the P position.
2. Connect the M-MDS to the DLC-2.
3. Turn off the electrical loads.
4. Verify that no DTCs are available.
5. Warm up the engine as follows.
(1) Start the engine.
(2) Perform no-load racing at 2,500—3,000 rpm
for 3 min. (ECT is approx. 80 °C {176 °F} or
more)
(3) Release the accelerator pedal. DLC-2
(4) Wait until the cooling fans stop.

ac9uuw00000115
Ignition Timing Inspection
1. Perform “Engine Tune-up Preparation”. (See 01-10-57 Engine Tune-up Preparation.)

Note
• The ignition timing cannot be adjusted.
• The M-MDS is required to verify the ignition timing.

2. Verify that the ignition timing (M-MDS: SPARKADV) is within the specification using M-MDS function.

Ignition timing
Approx. BTDC 13 °

3. Verify that ignition timing advances when the engine speed increases gradually.
• If it is not within the specification, refer to “ENGINE SYMPTOM TROUBLESHOOTING”. (See 01-03-3
ENGINE SYMPTOM TROUBLESHOOTING [MZI-3.5].)

Idle Speed Inspection

1. Perform “Engine Tune-up Preparation”. (See 01-10-57 Engine Tune-up Preparation.)

Note
• The idle speed cannot be adjusted.
• The M-MDS is required to verify the idle speed.

2. Verify that the idle speed (M-MDS: RPM) is within the specification using M-MDS.
Idle speed (P position)
No load: 570—670 rpm
Electrical load on: 630—730 rpm
Power steering oil pump operation: 600—700 rpm
A/C and heater operation: 570—850 rpm [-40—49 °C {-40—120 °F}]
Idle Mixture Inspection
1. Perform “Engine Tune-up Preparation”. (See 01-10-57 Engine Tune-up Preparation.)
2. Verify that the idle speed and ignition timing are within the specification. (See 01-10-57 Ignition Timing
Inspection.) (See 01-10-57 Idle Speed Inspection.)
3. Insert an exhaust gas analyzer into the tailpipe.
4. Verify that the CO and HC concentrations are within the specified regulation.
• If not within the regulation, refer to “ENGINE SYMPTOM TROUBLESHOOTING”. (See 01-03-3 ENGINE
SYMPTOM TROUBLESHOOTING [MZI-3.5].)
Idle mixture
HC concentration: Within the regulation
CO concentration: Within the regulation
End Of Sie

01-10–57
1890-1U-06H(01-11).fm 1 ページ ２００６年１２月２０日　水曜日　午前９時１０分

LUBRICATION [MZI-3.5]
01-11 LUBRICATION [MZI-3.5]
LUBRICATION SYSTEM OIL COOLER
LOCATION INDEX [MZI-3.5]. . . . . . . . . 01-11–1 REMOVAL/INSTALLATION
ENGINE OIL LEVEL INSPECTION [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-11–4
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-11–2 Oil Cooler Installation Note . . . . . . . . . . 01-11–5
ENGINE OIL REPLACEMENT OIL PAN REMOVAL/INSTALLATION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-11–2 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-11–5 01-11
OIL PRESSURE INSPECTION Engine Mounting/Dismounting . . . . . . . 01-11–7
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-11–3 Oil Pan Removal Note . . . . . . . . . . . . . . 01-11–8
OIL FILTER REPLACEMENT Oil Pan Installation Note . . . . . . . . . . . . 01-11–8
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-11–4 OIL PUMP REMOVAL/INSTALLATION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-11–10

End of Toc
LUBRICATION SYSTEM LOCATION INDEX [MZI-3.5]
WM: LUBRICATION SYSTEM

id0111e1800100

6
3
OIL PAN DRAIN
PLUG 5

ac9uuw00002189

1 Dipstick 4 Oil cooler

(See 01-11-2 ENGINE OIL LEVEL INSPECTION (See 01-11-4 OIL COOLER REMOVAL/
[MZI-3.5].) INSTALLATION [MZI-3.5].)
(See 01-11-2 ENGINE OIL REPLACEMENT [MZI- 5 Oil pan
3.5].) (See 01-11-5 OIL PAN REMOVAL/INSTALLATION
2 Oil pressure switch [MZI-3.5].)
(See 01-11-3 OIL PRESSURE INSPECTION [MZI- 6 Oil strainer
3.5].) (See 01-11-5 OIL PAN REMOVAL/INSTALLATION
3 Oil filter [MZI-3.5].)
(See 01-11-4 OIL FILTER REPLACEMENT [MZI- 7 Oil pump
3.5].) (See 01-11-10 OIL PUMP REMOVAL/
INSTALLATION [MZI-3.5].)

End Of Sie
WM: ENGINE OIL

01-11–1
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LUBRICATION [MZI-3.5]
ENGINE OIL LEVEL INSPECTION [MZI-3.5]
id0111e1800500
1. Position the vehicle on level ground.
2. Warm up the engine.
3. Stop the engine and allow approx. 5 min before continuing.
4. Remove the dipstick, wipe it clean, and reinstall it fully.
5. Remove the dipstick and verify that the oil level is
between the L and F marks on the dipstick.
• If the oil level is below the L mark, add engine
oil.
End Of Sie

L MARK F MARK

atraaw00000431

ENGINE OIL REPLACEMENT [MZI-3.5]

id0111e1800400

Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

Caution
• If engine oil is spilled on the exhaust system, wipe it off completely. If you fail to wipe the spilled
engine oil, it will produce fumes because of the heat.

1. Position the vehicle on level ground.

2. Remove the oil filler cap.
3. Remove the oil pan drain plug.
4. Drain the engine oil into a container.
5. Inspect the rubber seal of the oil pan drain plug and make sure there are no cracks, deterioration, or damage.
• If necessary, replace the oil pan drain plug.
6. Clean the flange surface (seal rubber) on the oil pan drain plug, then install the oil pan drain plug.

Oil pan drain plug tightening torque

27 N·m {2.8 kgf·m, 20 ft·lbf}

Note
• The amount of residual oil in the engine can vary according to factors such as the replacement method
and oil temperature. Verify the oil level after engine oil replacement.

7. Refill with the following type and amount of the engine oil.

Engine oil capacity (approx. quantity)

Oil replacement: 4.7 L {5.0 US qt, 4.2 Imp qt}
Oil and oil filter replacement: 5.2 L {5.5 US qt, 4.6 Imp qt}

01-11–2
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
LUBRICATION [MZI-3.5]
Engine oil specification
Item U.S.A. and CANADA Except U.S.A. and CANADA

SM
01-11
Engine oil grade

(ILSAC) (ILSAC)

API SM or ILSAC
Engine oil viscosity 5W-20

8. Install the oil filler cap.

9. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, repair or replace the applicable part.
10. Inspect the oil level. (See 01-11-2 ENGINE OIL LEVEL INSPECTION [MZI-3.5].)
End Of Sie
OIL PRESSURE INSPECTION [MZI-3.5]
WM: OIL PRESSURE

id0111e1800300

Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

1. Disconnect the negative battery cable.

2. Remove the engine cover.
3. Remove the fan control module No.2 with the connectors still connected. (Dual fan control module) (See 01-12-
14 FAN MOTOR REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the oil pressure switch.
5. Screw the SSTs into the oil pressure switch
installation hole. 49 0187 280A
6. Connect the negative battery cable.
7. Warm up the engine to normal operating
temperature.
8. Run the engine at the specified speed, and note
the gauge readings. 49 T018 007
• If not within the specification, inspect for the
cause and repair or replace if necessary.

Note 49 T018 006

• The oil pressure can vary with oil viscosity
ac9uuw00002360
and temperature.

Oil pressure (reference value) [oil temperature: 93.3 °C {200 °F}]

310—621 kPa {3.17—6.33 kgf/cm2, 45.0—90.0 psi} [2,000 rpm]

9. Stop the engine and wait until it is cool.

10. Disconnect the negative battery cable.
11. Remove the SSTs.

Caution
• Be sure there is no sealant adhering to the first two threads from the end of the oil pressure switch
to prevent a possible operation malfunction.

Revised 1/2007 (Ref. No. R009/07) 01-11–3

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
LUBRICATION [MZI-3.5]
12. Apply silicone sealant to the oil pressure switch
threads as shown in the figure.
13. Install the oil pressure switch. FIRST TWO THREADS

Tightening torque
10.7—24.5 N·m {1.1—2.4 kgf·m, 7.9—18.0
ft·lbf}

14. Install the fan control module No.2. (Dual fan SEALANT

control module) (See 01-12-14 FAN MOTOR AT LEAST THREE THREADS

REMOVAL/INSTALLATION [MZI-3.5].)
15. Connect the negative battery cable.
ac9uuw00002461
16. Start the engine and confirm that there is no oil
leakage.
• If there is oil leakage, repair or replace the applicable part.
17. Install the engine cover.
End Of Sie
OIL FILTER REPLACEMENT [MZI-3.5]
WM: OIL FILTER

id0111e1800700

Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

Caution
• If engine oil is spilled on the exhaust system, wipe it off completely. If you fail to wipe the spilled
engine oil, it will produce fumes because of the heat.

1. Remove the oil filter using a oil filter wrench.

2. Use a clean rag to wipe off the mounting surface
on the oil filter adapter and the oil filter.
3. Apply clean engine oil to the O-ring of a new oil
filter.
4. Install the oil filter until the O-ring contacts the
sealing surface.
5. Tighten the oil filter 3/4 turns by hand.
6. Start the engine and confirm that there is no oil
leakage.
• If there is oil leakage, repair or replace the
applicable part.
ac9uuw00002157
7. Inspect the oil level. (See 01-11-2 ENGINE OIL
LEVEL INSPECTION [MZI-3.5].)
End Of Sie
OIL COOLER REMOVAL/INSTALLATION [MZI-3.5]
WM: OIL COOLER

id0111e1800800

Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
3. Remove the air cleaner and fresh air duct component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
4. Remove the cooling fan component. (See 01-12-14 FAN MOTOR REMOVAL/INSTALLATION [MZI-3.5].)

01-11–4 Revised 1/2007 (Ref. No. R009/07)

1890-1U-06H(01-11).fm 5 ページ ２００６年１２月２０日　水曜日　午前９時１０分

LUBRICATION [MZI-3.5]
5. Remove the exhaust manifold insulator (LH). (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION
[MZI-3.5].)
6. Remove in the order indicated in the table.
7. Use a clean rag to wipe off the mounting surface on the oil filter adapter and the oil cooler.
8. Install in the reverse order of the removal.
9. Refill the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
10. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, repair or replace the applicable part. 01-11
11. Inspect the oil level. (See 01-11-2 ENGINE OIL LEVEL INSPECTION [MZI-3.5].)
12. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5].)
.

1 Water hose
2 Oil cooler
(See 01-11-5 Oil Cooler Installation Note.) 3 R OIL

3 O-ring

8.5—11.5
{87—117,
3 76—101}
R
OIL

1 1
N·m {kgf·cm, in·lbf}

ac9uuw00002158

Oil Cooler Installation Note

1. Tighten the oil cooler bolts in the order shown in
the figure. 4
1
End Of Sie
WM: OIL PAN

5
2

3
6

ac9uuw00002159

OIL PAN REMOVAL/INSTALLATION [MZI-3.5]

id0111e1800200

Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

Note
• The following procedure “OIL PAN REMOVAL/INSTALLATION” is performed after the engine and
transaxle component is removed from the vehicle.

1. Drain the engine oil. (See 01-11-2 ENGINE OIL REPLACEMENT [MZI-3.5].)
2. Remove the engine and transaxle component. (See 01-10-41 ENGINE REMOVAL/INSTALLATION [MZI-3.5].)

01-11–5
1890-1U-06H(01-11).fm 6 ページ ２００６年１２月２０日　水曜日　午前９時１０分

LUBRICATION [MZI-3.5]
3. Using a hoist, lower the engine and transaxle component on a level surface.

Warning
• Protect and stabilize the lowered engine and transaxle component with crossties to prevent injury
or damage due to roll over.

4. Remove the automatic transaxle. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION

[AW6A-EL, AW6AX-EL].)
5. Remove the drive plate. (See 05-17-58 DRIVE PLATE REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
6. Remove the dynamic chamber and throttle body as a single unit. (See 01-13-4 INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [MZI-3.5].)
7. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5].)
8. Remove the dipstick.
9. Remove the power steering oil pump drive belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-
3.5].)
10. Remove the power steering oil pump. (See 06-14-20 POWER STEERING OIL PUMP REMOVAL/
INSTALLATION.)
11. Remove the exhaust manifold (RH). (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
12. Remove the transfer bracket. (AWD) (See 03-16-4 TRANSFER REMOVAL/INSTALLATION.)
13. Install the engine to the SST (engine stand). (See 01-11-7 Engine Mounting/Dismounting.)
14. Remove the engine front cover. (See 01-10-11 TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.5].)
15. Remove in the order indicated in the table.
16. Install in the reverse order of removal.
17. Start the engine and:
(1) Inspect the runout and contact on the pulley and belt.
(2) Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage.
(3) Verify the ignition timing, idle speed and idle mixture. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
(4) Engine accessories operation.
18. Perform a road test.

OIL
R 3

8.5—11.5 N·m
{87—117 kgf·cm, 1
76—101 in·lbf}

SEALANT

18.5—21.5 18.5—21.5
{1.89—2.19, {1.89—2.19,
13.7—15.8} 13.7—15.8}
8.5—11.5 N·m
{87—117 kgf·cm,
76—101 in·lbf} N·m {kgf·m, ft·lbf}

ac9uuw00002179

1 Oil pan 2 Oil strainer

(See 01-11-8 Oil Pan Removal Note.) 3 O-ring
(See 01-11-8 Oil Pan Installation Note.)

01-11–6
1890-1U-06H(01-11).fm 7 ページ ２００６年１２月２０日　水曜日　午前９時１０分

LUBRICATION [MZI-3.5]
Engine Mounting/Dismounting
Mounting
1. Remove the WU-TWC (RH) bracket. (AWD)

WU-TWC (RH)
BRACKET

34—46 {3.5—4.6, 01-11

26—33}

N·m {kgf·m, ft·lbf}

ac9uuw00002180

2. Install the SSTs (arms) to the cylinder block four

49 L010 102
holes as shown in the figure, and hand-tighten the
bolts (M10 x 1.5T length 90 mm {3.55 in}).

ac9uuw00002181

3. Assemble the SSTs (bolts, nuts, and plate) to the

specified positions as shown in the figure. 49 L010 101

49 L010 105 49 L010 104

ac9uuw00002182

4. Assemble the SST (bolts, nuts, and plate) set in

Step 3 to the SST (arms) set in Step 2. PARALLEL
49 L010 101
5. Adjust the SSTs (bolts) so that approx. 20 mm
{0.79 in} of thread is exposed from the side of the 49 L010 102
SST (plate).
6. Make the SSTs (arms and plate) parallel by 49 L010 105
adjusting the SSTs (bolts and nuts). ENGINE
7. Tighten the SSTs (bolts and nuts) to affix the
SSTs firmly.

49 L010 104 49 L010 103 APPROX. 20 mm {0.79 in}

ac9uuw00002183

01-11–7
1890-1U-06H(01-11).fm 8 ページ ２００６年１２月２０日　水曜日　午前９時１０分

LUBRICATION [MZI-3.5]
8. Mount the engine on the SST (engine stand).
49 0107 680A
Warning
• Self-locking brake system of the engine
stand may not be effective when the
engine is held in an unbalanced position.
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury.
Never keep the engine in an unbalanced
position, and always hold the rotating
handle firmly when turning the engine.
ac9uuw00002184

Dismounting
1. Dismount in the reverse order of mounting.

Oil Pan Removal Note

1. Install two of the oil pan bolts temporarily into the
two threaded holes in the oil pan.
2. Alternately tighten the two bolts one turn at a time
until the oil pan-to-cylinder block seal is released.
3. Remove the oil pan.

ac9uuw00002185

Oil Pan Installation Note

Caution
• Apply silicon sealant in a single, unbroken line around the whole perimeter.
• The oil pan and bolts must be installed and the oil pan aligned to the cylinder block within 5 min of
sealant application. Final tightening of the oil pan bolts must be carried out within 60 min of
sealant application.
• Using bolts with the old seal adhering
could cause cracks in the cylinder block.

1. Completely clean and remove any oil, dirt, sealant DAMAGE

or other foreign material that may be adhering to
the cylinder block and oil pan.
2. When reusing the oil pan installation bolts, clean
any old sealant from the bolts.
OLD SEALANT

acxuuw00001993

01-11–8
1890-1U-06H(01-11).fm 9 ページ ２００６年１２月２０日　水曜日　午前１１時５５分

LUBRICATION [MZI-3.5]
3. Apply silicone sealant (Loctite 5900) to the oil pan
A
along the inside of the bolt holes as shown in the
figure.

Thickness
A: Approx. 3.0 mm {0.12 in}
B: 5.0—6.0 mm {0.20—0.23 in}
C: 10.0 mm {0.39 in} 01-11

C C

B B
ac9uuw00002251

4. Install the oil pan and the bolts to the cylinder block.
(1) Tighten the bolts in the order shown in the
figure. 12 8 4 2 6
Tightening torque 14 10
3.0 N·m {31 kgf·cm, 27 in·lbf}
16
(2) Loosen the bolts 180 °.
15
11
13 9 5 1 3 7

ac9uuw00002252

5. Using a straightedge, align the oil pan flush with

the rear of the cylinder block at the two areas as
shown.

ac9uuw00002187

6. Tighten the bolts in the order shown in the figure. A A A A A

12 8 4 2 6
Tightening torque
Bolt A: 18.5—21.5 N·m {1.89—2.19 kgf·m, A 14 10 A
13.7—15.8 ft·lbf}
Bolt B: 8.5—11.5 N·m {87—117 kgf·cm, 76— 16 B
101 in·lbf}
15 B
End Of Sie
WM: OIL PUMP
11 A
13 9 5 1 3 7
A A A A A A
ac9uuw00002188

01-11–9
1890-1U-06H(01-11).fm 10 ページ ２００６年１２月２０日　水曜日　午前９時１０分

LUBRICATION [MZI-3.5]
OIL PUMP REMOVAL/INSTALLATION [MZI-3.5]
id0111e1800600

Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

Note
• The following procedure “OIL PUMP REMOVAL/INSTALLATION” is performed after the engine and
transaxle component is removed from the vehicle.

1. Drain the engine oil. (See 01-11-2 ENGINE OIL REPLACEMENT [MZI-3.5].)
2. Remove the engine and transaxle component. (See 01-10-41 ENGINE REMOVAL/INSTALLATION [MZI-3.5].)
3. Secure the engine and transaxle component
using a hoist and the SST.
4. Remove the dynamic chamber and throttle body
as a single unit. (See 01-13-4 INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION [MZI-3.5].) 49 L017 5A0
5. Remove the ignition coils. (See 01-18-2
IGNITION COIL REMOVAL/INSTALLATION [MZI-
3.5].)
6. Remove the dipstick.
7. Remove the power steering oil pump drive belt.
(See 01-10-4 DRIVE BELT REMOVAL/
INSTALLATION [MZI-3.5].)
8. Remove the power steering oil pump. (See 06-14-
20 POWER STEERING OIL PUMP REMOVAL/
INSTALLATION.)
9. Remove the timing chain component. (See 01-10-
11 TIMING CHAIN REMOVAL/INSTALLATION
[MZI-3.5].)
10. Remove in the order indicated in the table.
11. Install in the reverse order of removal.
12. Start the engine and:
(1) Inspect the runout and contact on the pulley
and belt.
(2) Inspect for engine oil, engine coolant, ATF, ac9uuw00001882
power steering fluid and fuel leakage.
(3) Verify the ignition timing, idle speed and idle
mixture. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
(4) Engine accessories operation.
13. Inspect the oil pressure. (See 01-11-3 OIL PRESSURE INSPECTION [MZI-3.5].)
14. Perform a road test.

01-11–10
1890-1U-06H(01-11).fm 11 ページ ２００６年１２月２０日　水曜日　午前９時１０分

LUBRICATION [MZI-3.5]

01-11

8.5—11.5 {87—117, 76—101}

OIL
R 2

8.5—11.5 {87—117, 76—101}

N·m {kgf·cm, in·lbf}

ac9uuw00002192

1 Oil pump 2 O-ring

End Of Sie

01-11–11
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
COOLING SYSTEM [MZI-3.5]
01-12 COOLING SYSTEM [MZI-3.5]
COOLING SYSTEM LOCATION INDEX Thermostat Installation Note . . . . . . . . . 01-12–11
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-12–2 O-ring Installation Note . . . . . . . . . . . . . 01-12–11
COOLING SYSTEM SERVICE THERMOSTAT INSPECTION
WARNINGS [MZI-3.5] . . . . . . . . . . . . . . 01-12–3 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-12–11
ENGINE COOLANT LEVEL INSPECTION WATER PUMP
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-12–3 REMOVAL/INSTALLATION 01-12
ENGINE COOLANT PROTECTION [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-12–12
INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-12–4 Upper Timing Chain Guide (RH)
ENGINE COOLANT REPLACEMENT Removal Note . . . . . . . . . . . . . . . . . . . 01-12–13
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-12–5 Water Pump Removal Note. . . . . . . . . . 01-12–14
ENGINE COOLANT LEAKAGE Water Pump Installation Note . . . . . . . . 01-12–14
INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-12–6 FAN MOTOR
COOLING SYSTEM CAP INSPECTION REMOVAL/INSTALLATION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-12–7 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-12–14
COOLANT RESERVE TANK ATF Oil Cooler Pipe
REMOVAL/INSTALLATION Removal Note . . . . . . . . . . . . . . . . . . . 01-12–16
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-12–7 Cooling Fan Component
RADIATOR REMOVAL/INSTALLATION Removal Note . . . . . . . . . . . . . . . . . . . 01-12–16
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-12–8 FAN MOTOR INSPECTION
Upper Mount Rubber Bracket [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-12–16
Removal Note . . . . . . . . . . . . . . . . . . 01-12–10 Part Inspection . . . . . . . . . . . . . . . . . . . 01-12–16
Radiator Removal Note . . . . . . . . . . . . 01-12–10 FAN CONTROL MODULE INSPECTION
THERMOSTAT [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-12–16
REMOVAL/INSTALLATION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-12–10

End of Toc
WM: COOLING SYSTEM

01-12–1
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
COOLING SYSTEM [MZI-3.5]
COOLING SYSTEM LOCATION INDEX [MZI-3.5]
id0112d1800100

1
DUAL FAN CONTROL MODULE

2
10

4 7

8
7

5
ac9uuw00002628

1 Cooling system cap 3 Radiator

(See 01-12-7 COOLING SYSTEM CAP (See 01-12-4 ENGINE COOLANT PROTECTION
INSPECTION [MZI-3.5].) INSPECTION [MZI-3.5].)
2 Coolant reserve tank (See 01-12-5 ENGINE COOLANT REPLACEMENT
(See 01-12-3 ENGINE COOLANT LEVEL [MZI-3.5].)
INSPECTION [MZI-3.5].) (See 01-12-6 ENGINE COOLANT LEAKAGE
(See 01-12-7 COOLANT RESERVE TANK INSPECTION [MZI-3.5].)
REMOVAL/INSTALLATION [MZI-3.5].) (See 01-12-8 RADIATOR REMOVAL/
INSTALLATION [MZI-3.5].)
4 Thermostat
(See 01-12-10 THERMOSTAT REMOVAL/
INSTALLATION [MZI-3.5].)
(See 01-12-11 THERMOSTAT INSPECTION [MZI-
3.5].)

01-12–2 Revised 1/2007 (Ref. No. R009/07)

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
COOLING SYSTEM [MZI-3.5]
5 Water pump 8 Fan control module (Single fan control module)
(See 01-12-12 WATER PUMP REMOVAL/ (See 01-12-16 FAN CONTROL MODULE
INSTALLATION [MZI-3.5].) INSPECTION [MZI-3.5].)
6 Cooling fan motor No.1 9 Fan control module No.1 (Dual fan control module)
(See 01-12-14 FAN MOTOR REMOVAL/ (See 01-12-16 FAN CONTROL MODULE
INSTALLATION [MZI-3.5].) INSPECTION [MZI-3.5].)
(See 01-12-16 FAN MOTOR INSPECTION [MZI- 10 Fan control module No.2 (Dual fan control module)
3.5].) (See 01-12-16 FAN CONTROL MODULE 01-12
7 Cooling fan motor No.2 INSPECTION [MZI-3.5].)
(See 01-12-14 FAN MOTOR REMOVAL/
INSTALLATION [MZI-3.5].)
(See 01-12-16 FAN MOTOR INSPECTION [MZI-
3.5].)

End Of Sie
COOLING SYSTEM SERVICE WARNINGS [MZI-3.5]
id0112d1800200

Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
• Depending on the vehicle, the cooling fan may operate suddenly even when the ignition switch is
turned off. Therefore, keep hands and tools away from the cooling fan even if the cooling fan is not
operating to prevent injury to personnel or damage to the cooling fan. Always disconnect the
negative battery cable when servicing the cooling fan or parts near the cooling fan.

End Of Sie
ENGINE COOLANT LEVEL INSPECTION [MZI-3.5]
WM: ENGINE COOLANT

id0112d1800300

Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.

Note
• If the “FL22” mark is shown on or near the
cooling system cap, use FL22 type engine
coolant.
• FL22 type engine coolant is shipped as a
diluted solution. Use the solution as is when
replacing coolant.

acxuuw00002056

Revised 1/2007 (Ref. No. R009/07) 01-12–3

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
COOLING SYSTEM [MZI-3.5]
1. Verify that the engine coolant level in the coolant
reserve tank is between the F and L marks.
• If the engine coolant level is below the L mark,
add engine coolant.
End Of Sie

ac9uuw00002193
ENGINE COOLANT PROTECTION INSPECTION [MZI-3.5]
id0112d1800400
1. Measure the engine coolant temperature and specific gravity using a thermometer and a hydrometer.

Caution
• Use engine coolant at a concentration that meets the environmental conditions in which the
vehicle is driven, otherwise engine damage could occur.
• The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to
prevent corrosion and freezing.
• Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could
damage the cooling system.
• Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut
down on the coolant’s effectiveness.
• Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.

Note
• If the “FL22” mark is shown on or near the
cooling system cap, use FL22 type engine
coolant.
• FL22 type engine coolant is shipped as a
diluted solution. Use the solution as is when
replacing coolant.

acxuuw00002058
2. Determine the engine coolant protection level by
SPECIFIC COOLANT PROTECTION
referring to the graph shown in the figure. (EXCEPT FL22 TYPE ENGINE COOLANT)
GRAVITY
• If the engine coolant protection level is not
1.10
correct, add water or engine coolant.
End Of Sie 1.09

1.08

1.07 55%
1.06
45%
1.05
35%
1.04

1.03

1.02

1.01

1.00
0 5 10 15 20 25 30 35 40 45 50
{32} {41} {50} {59} {68} {77} {86} {95} {104} {113} {122}

COOLANT TEMPERATURE °C {°F}

acxuuw00002059

01-12–4
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
COOLING SYSTEM [MZI-3.5]
ENGINE COOLANT REPLACEMENT [MZI-3.5]
id0112d1800600

Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while 01-12
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.

Caution
• Use engine coolant at a concentration that meets the environmental conditions in which the
vehicle is driven, otherwise engine damage could occur.
• The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to
prevent corrosion and freezing.
• Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could
damage the cooling system.
• Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut
down on the coolant's effectiveness.
• Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.

Note
• If the “FL22” mark is shown on or near the
cooling system cap, use FL22 type engine
coolant.
• FL22 type engine coolant is shipped as a
diluted solution. Use the solution as is when
replacing coolant.

Engine coolant capacity (approx. quantity)

Dual fan control module : 11.7 L {12.4 US qt,
10.3 Imp qt}
Single fan control module : 11.1 L {11.7 US
qt, 9.77 Imp qt} acxuuw00002061

1. Remove the cooling system cap.

COOLING
SYSTEM CAP

COOLANT
RESERVE TANK

FRONT

ac9uuw00002194

2. Remove the radiator drain plug and drain the

engine coolant into a container.
3. Flush the cooling system with water until all traces
of color are gone.
4. Let the system drain completely.
5. Tighten the radiator drain plug.

Tightening torque
1.5—2.4 N·m {15—25 kgf·cm, 13—21 in·lbf}
RADIATOR DRAIN PLUG
6. Referring to the following chart, select the correct
volume percentage of the water and engine
ac9uuw00002195
coolant.

Revised 1/2007 (Ref. No. R009/07) 01-12–5

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
COOLING SYSTEM [MZI-3.5]
Antifreeze solution mixture percentage (Except FL22 type engine coolant)
Volume percentage (%)
Engine coolant protection Gravity at 20 °C {68 °F}
Water Coolant
Above -16 °C {3 °F} 65 35 1.057
Above -26 °C {-15 °F} 55 45 1.072
Above -40 °C {-40 °F} 45 55 1.086

7. Refill the engine coolant into the coolant reserve tank up to the F mark on the tank.
8. Install the cooling system cap.

Caution
• If the water temperature gauge rises too high, stop the engine and decrease the engine coolant
temperature to prevent overheating. Then, verify the malfunctioning part and repair or replace it.
• If the engine coolant level in the coolant reserve tank is below the L mark during engine coolant air
bleeding operation, stop the engine, and after the engine coolant temperature decreases, add
engine coolant. Then, resume the engine coolant air bleeding operation.

9. Start the engine and warm up the engine by idling.

10. After the engine warms up, perform the following steps. At this time, be careful of the engine coolant
temperature to prevent overheating.

Note
• If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to
the idle speed. This is does not indicate a malfunction.

(1) Run the engine at approx. 4,000 rpm for 1 min.

(2) Run the engine at idle for 1 min.
(3) Repeat steps (1), (2) approx. 2 times.
(4) Operate the heater at the maximum temperature and airflow, and verify that hot air blows from vent.
11. Stop the engine, and inspect the engine coolant level after the engine coolant temperature decreases. If it is
low, repeat steps 7—10.
12. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5].)
End Of Sie
ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5]
id0112d1800500

Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.

1. Inspect the engine coolant level. (See 01-12-3 ENGINE COOLANT LEVEL INSPECTION [MZI-3.5].)
2. Remove the cooling system cap.
3. Install the SST and a radiator cap tester to the
coolant reserve tank filler port.
4. Apply pressure using the radiator cap tester.
49 9200 145
Caution
• Applying more than 122.6 kPa {1.25 kgf/
cm2, 17.8 psi} can damage the hoses,
fittings, and other components, and
cause leakage.

Engine coolant leakage inspection pressure

122.6 kPa {1.25 kgf/cm2, 17.8 psi} [1 min] acxuuw00002060

5. When pressurizing the cooling system, verify that the pressure is maintained.
• If the gauge needle drops, it may indicate water leakage. Repair or replace the applicable part.
End Of Sie
WM: COOLING SYSTEM CAP

01-12–6
1890-1U-06H(01-12).fm 7 ページ ２００６年１２月１９日　火曜日　午前１０時３８分

COOLING SYSTEM [MZI-3.5]

COOLING SYSTEM CAP INSPECTION [MZI-3.5]
id0112d1801500

Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
01-12
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Clean the cooling system cap and the sealed part.
2. Inspect the cooling system cap for cracks or everted seal.
• If there is any malfunction, replace the cooling system cap.
3. Attach the cooling system cap to the SST and a
radiator cap tester.
49 9200 145
4. Hold the cooling system cap downward and apply
pressure gradually. Verify that the pressure is held
stable for 10 s.
• If the pressure is not held stable, replace the
cooling system cap.

Cooling system cap valve opening pressure

93.2—122.6 kPa {0.95—1.25 kgf/cm2, 13.5— COOLING SYSTEM CAP
17.8 psi}
acxuuw00002014
End Of Sie
COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZI-3.5]
WM: COOLANT RESERVE TANK

id0112d1801000

Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.

1. Drain the engine coolant until the coolant reserve tank becomes empty. (See 01-12-5 ENGINE COOLANT
REPLACEMENT [MZI-3.5].)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Refill the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
5. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5].)
.

1 Hose
6.9—11.8
2 Coolant reserve tank {71—120,
2
62—104}
End Of Sie
WM: RADIATOR

1
N·m {kgf·cm, in·lbf}
ac9uuw00002176

01-12–7
1890-1U-06H(01-12).fm 8 ページ ２００６年１２月１９日　火曜日　午前１０時３８分

COOLING SYSTEM [MZI-3.5]

RADIATOR REMOVAL/INSTALLATION [MZI-3.5]
id0112d1801400

Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
3. Remove the air cleaner and fresh air duct component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
4. Remove the cooling fan component. (See 01-12-14 FAN MOTOR REMOVAL/INSTALLATION [MZI-3.5].)
5. Disconnect the ATF oil cooler hose from the radiator.
6. Remove in the order indicated in the table.
7. Install in the reverse order of the removal.
8. Refill the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
9. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5].)
10. Inspect the ATF level. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)

01-12–8
1890-1U-06H(01-12).fm 9 ページ ２００６年１２月１９日　火曜日　午前１０時３８分

COOLING SYSTEM [MZI-3.5]

1
A

6
C

01-12
1

2
5
3 D

4
A

C
B

ac9uuw00002168

1 Coolant reserve tank hose 4 Upper mount rubber bracket

2 Lower radiator hose (See 01-12-10 Upper Mount Rubber Bracket
Removal Note.)
3 Oil cooler water hose
5 Upper mount rubber
6 Radiator
(See 01-12-10 Radiator Removal Note.)

01-12–9
1890-1U-06H(01-12).fm 10 ページ ２００６年１２月１９日　火曜日　午前１０時３８分

COOLING SYSTEM [MZI-3.5]

Upper Mount Rubber Bracket Removal Note

Caution
• Do not apply force excessively and in the directions that are not specified, otherwise the upper
mount rubber bracket could be damaged.

1. Insert a flathead screwdriver into the upper mount

rubber bracket notch.

NOTCH

UPPER MOUNT
RUBBER BRACKET

ac9uuw00002169

2. Apply force in the direction shown by the arrow.

ac9uuw00002170

Radiator Removal Note

1. Remove the radiator from above the engine compartment.
End Of Sie
THERMOSTAT REMOVAL/INSTALLATION [MZI-3.5]
WM: THERMOSTAT

id0112d1801200

Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
3. Remove the air cleaner and fresh air duct component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Refill the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)

01-12–10
1890-1U-06H(01-12).fm 11 ページ ２００６年１２月１９日　火曜日　午前１０時３８分

COOLING SYSTEM [MZI-3.5]

7. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5].)
.

1 Thermostat cover
2 O-ring
(See 01-12-11 O-ring Installation Note.)
3 Thermostat
(See 01-12-11 Thermostat Installation Note.)
2
01-12
1 8.5—11.5
{87—117,
76—101}
3

N·m {kgf·cm, in·lbf}

ac9uuw00002166

Thermostat Installation Note

1. Install the thermostat into the thermostat case
with the jiggle pin at the top.
JIGGLE PIN

ac9uuw00002167

O-ring Installation Note

1. Clean and inspect the O-ring.
— Install a new O-ring if necessary.
2. Apply clean engine coolant to the O-ring.
3. Install the O-ring.
End Of Sie
THERMOSTAT INSPECTION [MZI-3.5]
id0112d1801300
1. Inspect the thermostat for the following.

Warning
• During inspection, the thermostat and water are extremely hot and can cause severe burns. Do not
touch the thermostat and water.

• The valve should not open under normal temperature.

• Opening temperature and valve lift
— If there is a malfunction, replace the thermostat.

Thermostat initial-opening temperature

79.5—83.3 °C {175.2—181.9 °F}

Thermostat full-open temperature

94.5 °C {202.1 °F}

Thermostat full-open lift

More than 8.1 mm {0.32 in}

End Of Sie
WM: WATER PUMP

01-12–11
1890-1U-06H(01-12).fm 12 ページ ２００６年１２月１９日　火曜日　午前１０時３８分

COOLING SYSTEM [MZI-3.5]

WATER PUMP REMOVAL/INSTALLATION [MZI-3.5]
id0112d1800700

Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.

Note
• The following procedure “WATER PUMP REMOVAL/INSTALLATION” is performed after the engine and
transaxle component is removed from the vehicle.

1. Drain the engine oil. (See 01-11-2 ENGINE OIL REPLACEMENT [MZI-3.5].)
2. Remove the engine and transaxle component. (See 01-10-41 ENGINE REMOVAL/INSTALLATION [MZI-3.5].)
3. Secure the engine and transaxle component
using a hoist and the SST.
4. Remove the dynamic chamber and throttle body
as a single unit. (See 01-13-4 INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION [MZI-3.5].) 49 L017 5A0
5. Remove the ignition coils. (See 01-18-2
IGNITION COIL REMOVAL/INSTALLATION [MZI-
3.5].)
6. Remove the dipstick.
7. Remove the power steering oil pump drive belt.
(See 01-10-4 DRIVE BELT REMOVAL/
INSTALLATION [MZI-3.5].)
8. Remove the power steering oil pump. (See 06-14-
20 POWER STEERING OIL PUMP REMOVAL/
INSTALLATION.)
9. Remove the timing chain component. (See 01-10-
11 TIMING CHAIN REMOVAL/INSTALLATION
[MZI-3.5].)
10. Remove in the order indicated in the table.
11. Install in the reverse order of removal.
12. Start the engine and:
(1) Inspect the runout and contact on the pulley
and belt.
(2) Inspect for engine oil, engine coolant, ATF, ac9uuw00001882
power steering fluid and fuel leakage.
(3) Verify the ignition timing, idle speed and idle
mixture. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
(4) Engine accessories operation.
13. Perform a road test.

01-12–12
1890-1U-06H(01-12).fm 13 ページ ２００６年１２月１９日　火曜日　午前１０時３８分

COOLING SYSTEM [MZI-3.5]

8.5—11.5 {87—117, 76—101}

2

8.5—11.5 {87—117, 76—101}

1 01-12

R 4

3
8.5—11.5 {87—117, 76—101}
N·m {kgf·cm, in·lbf}

ac9uuw00002255

1 Upper timing chain guide (LH) 3 Water pump

2 Upper timing chain guide (RH) (See 01-12-14 Water Pump Removal Note.)
(See 01-12-13 Upper Timing Chain Guide (RH) (See 01-12-14 Water Pump Installation Note.)
Removal Note.) 4 Gasket

Upper Timing Chain Guide (RH) Removal Note

1. Loosen the upper timing chain guide (RH) bolt A. UPPER TIMING CHAIN GUIDE (RH)
2. Remove the upper timing chain guide (RH) bolt B. A

ac9uuw00002197

3. Move the upper timing chain guide (RH) as UPPER TIMING CHAIN GUIDE (RH)
shown. A
4. Retighten the bolt A.

ac9uuw00002198

01-12–13
1890-1U-06H(01-12).fm 14 ページ ２００６年１２月１９日　火曜日　午前１０時３８分

COOLING SYSTEM [MZI-3.5]

Water Pump Removal Note

Note
• When the water pump is removed, the engine coolant may flow through the cylinder block and penetrate
the oil pan. To prevent the engine coolant from accumulating in the oil pan, remove the oil pan drain plug
before removing the water pump.

1. Remove the oil pan drain plug.

2. To prevent engine coolant from penetrating the oil
pan, line the cylinder block with plastic sheeting
as shown in the figure before removing the water
pump.
WATER
PUMP

PLASTIC
SHEETING

ac9uuw00002384

Water Pump Installation Note

1. Tighten the water pump bolts in the order shown
in the figure. 1
3
5
Tightening torque
8.5—11.5 N·m {87—117 kgf·cm, 76—101
in·lbf} 7
8
End Of Sie
WM: COOLING FAN MOTOR

4
2 6
ac9uuw00002199

FAN MOTOR REMOVAL/INSTALLATION [MZI-3.5]

id0112d1801600

Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
3. Remove the air cleaner and fresh air duct component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
4. Remove the engine cover.
5. Remove the dipstick.
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Refill the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
9. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5].)

01-12–14
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
COOLING SYSTEM [MZI-3.5]

2 1
1

1.7—3.3 {18—33, 16—28} 1.7—3.3

1.8—3.3
5.9—8.3 {18—33,
{61—84, 53—72}
{19—33,
16—28} 01-12
1.8—3.3 17—28}
{19—33, 11
17—28}
15 11

2.7—5.0
{28—50, 10
25—43} 8
13
7 15
14 9
14
5.9—8.3
{61—84, 53—72}
DUAL FAN CONTROL MODULE

4.9—7.9 A
{50—80,
44—69}
12

7.8—10.8
{80—110, 70—95}

3 7.8—10.8
{80—110, 70—95}
5

4 A
6

N·m {kgf·cm, in·lbf}

ac9uuw00002629

1 Connector 8 Fan control module (Single fan control module)

2 Wiring harness 9 Fan control module No.1 (Dual fan control module)
3 Relay box 10 Fan control module No.2 (Dual fan control module)
4 Upper radiator hose 11 Heat insulator
5 Oil cooler water hose 12 Cooling fan No.1
6 ATF oil cooler pipe 13 Cooling fan No.2
(See 01-12-16 ATF Oil Cooler Pipe Removal Note.) 14 Cooling fan motor No.1
7 Cooling fan component 15 Cooling fan motor No.2
(See 01-12-16 Cooling Fan Component Removal
Note.)

Revised 1/2007 (Ref. No. R009/07) 01-12–15

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
COOLING SYSTEM [MZI-3.5]
ATF Oil Cooler Pipe Removal Note
1. Remove the ATF oil cooler pipe with the hoses still connected. Position the ATF oil cooler pipe so that it is out of
the way.

Cooling Fan Component Removal Note

1. Remove the cooling fan component from above the engine compartment.
End Of Sie
FAN MOTOR INSPECTION [MZI-3.5]
id0112d1800900
Part Inspection
1. Verify that the battery is fully charged. (See 01-17-2 BATTERY INSPECTION [MZI-3.5].)
2. Disconnect the cooling fan motor connector (fan control module side, 2 terminals).
3. Install a tester and battery to the cooling fan
motor connector as shown in the figure. B
4. Verify that each fan motors operate smoothly at COOLING FAN
the standard current. MOTOR
• If there is any malfunction, replace the NO.1, NO.2
applicable part. CONNECTOR

A
Cooling fan motor standard current [Single
Fan Control Module]
No.1, No.2: 11.2—15.2 A COOLING FAN MOTOR NO.1, NO.2 CONNECTOR

Cooling fan motor standard current [Dual Fan B A

Control Module]
No.1, No.2: 17—23 A

End Of Sie
WM: FAN CONTROL MODULE

acxuuw00002065

FAN CONTROL MODULE INSPECTION [MZI-3.5]

id0112d1801100
1. Connect the M-MDS to the DLC-2.
2. Start and warm up the engine.
3. Monitor the engine coolant temperature with the
M-MDS.

DLC-2

ac9uuw00002177

4. Measure the voltage at terminal A of the fan

control module connector (2 terminal) as shown in
the table. FAN CONTROL MODULE CONNECTOR
• If not within the specification, inspect the input
signals from the following parts.
A B
— Cylinder Head Temperature (CHT) sensor
— Refrigerant pressure switch (middle)

ac9uuw00002178

01-12–16 Revised 1/2007 (Ref. No. R009/07)

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
COOLING SYSTEM [MZI-3.5]
Single fan control module
Inspection
Result
Condition A/C Engine coolant temp.
IG SW ON or idling OFF Less than 96 °C {205 °F} 0 V (Fan stops.)
Idling OFF 96—106 °C {205—223 °F} 4.11—10.29 V
Idling ON*1 96—106 °C {205—223 °F} Approx. 6.4 V
Idling ON*2 96—106 °C {205—223 °F} Approx. 7.7 V 01-12
Idling OFF More than 106 °C {223 °F} B+

Dual fan control module

Inspection
Result
Condition A/C Engine coolant temp.
IG SW ON or idling OFF Less than 96 °C {205 °F} 0 V (Fan stops.)
Idling OFF 96—106 °C {205—223 °F} 4.11—10.29 V
Idling ON*1 96—106 °C {205—223 °F} Approx. 6.6 V
Idling ON*2 96—106 °C {205—223 °F} Approx. 7.5 V
Idling OFF More than 106 °C {223 °F} B+

*1 : Refrigerant pressure switch (middle) is off.

*2 : Refrigerant pressure switch (middle) is on.

5. If all the above parts are normal, replace the fan control module.
End Of Sie

Revised 1/2007 (Ref. No. R009/07) 01-12–17

1890-1U-06H(01-13).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時４２分

INTAKE-AIR SYSTEM [MZI-3.5]

01-13 INTAKE-AIR SYSTEM [MZI-3.5]
INTAKE-AIR SYSTEM Dynamic Chamber
LOCATION INDEX [MZI-3.5]. . . . . . . . . 01-13–1 Installation Note . . . . . . . . . . . . . . . . . 01-13–6
INTAKE-AIR SYSTEM DIAGRAM AIR CLEANER ELEMENT
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-13–2 INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-13–6
INTAKE-AIR SYSTEM VACUUM THROTTLE BODY INSPECTION
HOSE ROUTING DIAGRAM [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-13–7 01-13
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-13–3 Resistance Inspection . . . . . . . . . . . . . . 01-13–7
INTAKE-AIR SYSTEM Circuit Open/Short Inspection . . . . . . . . 01-13–7
REMOVAL/INSTALLATION ACCELERATOR PEDAL
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-13–4 REMOVAL/INSTALLATION
Intake Manifold Removal Note . . . . . . . 01-13–5 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-13–8
Intake Manifold Installation Note . . . . . 01-13–6

End of Toc
INTAKE-AIR SYSTEM LOCATION INDEX [MZI-3.5]
WM: INTAKE-AIR SYSTEM

id0113c1801700

5
3
6
4

2
1
ac9uuw00000064

1 Air cleaner 4 Throttle body

(See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/ (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].) INSTALLATION [MZI-3.5].)
(See 01-13-6 AIR CLEANER ELEMENT (See 01-13-7 THROTTLE BODY INSPECTION
INSPECTION [MZI-3.5].) [MZI-3.5].)
2 Fresh-air duct 5 Dynamic chamber
(See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/ (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].) INSTALLATION [MZI-3.5].)
3 Resonance chamber 6 Intake manifold
(See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/ (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].) INSTALLATION [MZI-3.5].)
7 Accelerator pedal
(See 01-13-8 ACCELERATOR PEDAL REMOVAL/
INSTALLATION [MZI-3.5].)

01-13–1
1890-1U-06H(01-13).fm 2 ページ ２００６年１２月１９日　火曜日　午前１０時４２分

INTAKE-AIR SYSTEM [MZI-3.5]

End Of Sie

INTAKE-AIR SYSTEM DIAGRAM [MZI-3.5]

id0113c1801600

FRESH-AIR DUCT
DYNAMIC CHAMBER THROTTLE BODY

AIR CLEANER

RESONANCE CHAMBER

INTAKE MANIFOLD

:INTAKE AIR FLOW

:TO PCM

ac9uuw00000004

End Of Sie

01-13–2
1890-1U-06H(01-13).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時４２分

INTAKE-AIR SYSTEM [MZI-3.5]

INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [MZI-3.5]
id0113c1890000

PCV VALVE

PCV VALVE HEATER FITTING

PURGE SOLENOID VALVE

01-13

TO MASTER BACK

TO CHARCOAL CANISTER

TO MASTER BACK

VENTILATION HOSE

ac9uuw00000003

End Of Sie

01-13–3
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INTAKE-AIR SYSTEM [MZI-3.5]

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5]
id0113c1801900

Warning
• When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the intake-air system.
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”.
1. Complete the “BEFORE REPAIR PROCEDURE”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
2. Remove the battery. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Complete the “AFTER REPAIR PROCEDURE”. (See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)
8.5—11.5
{87—117,
76—101} 13

12

11
8 4.5—6.3
{46—64,
R A
40—55}
R 7

8.5—11.5 OIL
9 10
{87—117, R
76—101}
OIL

R A 8.5—11.5 6
{87—117,
76—101}

15 14
2.5—3.4
4 {26—34,
23—30}
16
5

7.9—11.7 {81—119, 70—103}

3
R

2
N·m {kgf·cm, in·lbf}
ac9uuw00000266

01-13–4
1890-1U-06H(01-13).fm 5 ページ ２００６年１２月１９日　火曜日　午前１０時４２分

INTAKE-AIR SYSTEM [MZI-3.5]

1 Air cleaner case 12 Vacuum hose (to master back)
2 Fresh-air duct 13 Dynamic chamber
3 Air cleaner element (See 01-13-6 Dynamic Chamber Installation Note.)
4 MAF/IAT sensor connector 14 Fuel hose
(See 01-14-22 QUICK RELEASE CONNECTOR
5 Air cleaner cover (FUEL SYSTEM) REMOVAL/INSTALLATION [MZI-
6 Vacuum hose (to master back) 3.5].)
7 Ventilation hose 15 Fuel distributor
(See 01-16-15 QUICK RELEASE CONNECTOR
01-13
(See 01-14-23 FUEL INJECTOR REMOVAL/
(EMISSION SYSTEM) REMOVAL/INSTALLATION INSTALLATION [MZI-3.5].)
[MZI-3.5].) 16 Intake manifold
8 Resonance chamber (See 01-13-5 Intake Manifold Removal Note.)
9 TP sensor connector (See 01-13-6 Intake Manifold Installation Note.)
10 Throttle body
11 Vacuum hose (to purge solenoid valve)
(See 01-16-15 QUICK RELEASE CONNECTOR
(EMISSION SYSTEM) REMOVAL/INSTALLATION
[MZI-3.5].)

Intake Manifold Removal Note

1. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
2. Disconnect the upper radiator hose.

INTAKE MANIFOLD

UPPER
RADIATOR WATER HOSE
HOSE

LOWER
RADIATOR
HOSE

THERMOSTAT
COMPONENT

WATER INLET
PIPE

ac9uuw00002457

3. Disconnect the lower radiator hose.

4. Disconnect the two water hose from the thermostat component.
5. Disconnect the thermostat component side of the water inlet pipe which is under the intake manifold.
6. Remove the intake manifold and thermostat component as a single unit.

01-13–5
1890-1U-06H(01-13).fm 6 ページ ２００６年１２月１９日　火曜日　午前１０時４２分

INTAKE-AIR SYSTEM [MZI-3.5]

7. Remove the thermostat component from the
INTAKE MANIFOLD
intake manifold.

THERMOSTAT
COMPONENT

8.5—11.5 {87—117,
76—101}
ac9uuw00002458

Intake Manifold Installation Note

1. Tighten the intake manifold installation bolts in the
order shown.

Intake manifold installation bolt tightening 6 2 4 8

torque
9
8.5—11.5 N·m {87—117 kgf·cm, 76—101
in·lbf}

7 1 5 10
3

ac9uuw00000417

Dynamic Chamber Installation Note

1. Tighten the dynamic chamber installation bolts in
the order shown.

Dynamic chamber installation bolt tightening

torque
8.5—11.5 N·m {87—117 kgf·cm, 76—101 3 6
in·lbf}

End Of Sie
WM: AIR CLEANER

4 2 1 5
ac9uuw00000418

AIR CLEANER ELEMENT INSPECTION [MZI-3.5]

id0113c1800800
1. Remove the air cleaner element. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
2. Verify that the air cleaner element surface is free of dirt.
• If there is dirt, use an air gun or similar tool to clean the element.
• If the replacement time limit has passed, replace the element.
End Of Sie
WM: THROTTLE BODY

01-13–6
1890-1U-06H(01-13).fm 7 ページ ２００６年１２月１９日　火曜日　午前１０時４２分

INTAKE-AIR SYSTEM [MZI-3.5]

THROTTLE BODY INSPECTION [MZI-3.5]
id0113c1802600

Note
• Perform the following inspection only when directed.
Resistance Inspection
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
3. Disconnect the throttle body connector. 01-13
4. Measure the resistance between throttle body terminals A and B.
• If not as specified, replace the throttle body. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
• If as specified, carry out the “Circuit Open/Short Inspection”.

Throttle body resistance

1—900 ohms

F E D C B A

THROTTLE ACTUATOR

ac9uuw00000192

Circuit Open/Short Inspection

1. Disconnect the PCM connector.
2. Inspect the following wiring harnesses for open or
short (continuity check). THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

F E D C B A

ac9uuw00000934

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00000935

01-13–7
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INTAKE-AIR SYSTEM [MZI-3.5]

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
— Throttle body terminal A and PCM terminal 2BO
— Throttle body terminal B and PCM terminal 2BR

Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
— Throttle body terminal A and power supply
— Throttle body terminal A and ground
— Throttle body terminal B and power supply
— Throttle body terminal B and ground
End Of Sie
ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZI-3.5]
WM: ACCELERATOR PEDAL

id0113c1801400
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the dashboard under cover (Driver side). (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
3. Remove in the order indicated in the table. .

7.8—10.8
1 Connector {80—110,
70—95}
2 Accelerator pedal

4. Install in the reverse order of removal. 1

End Of Sie
7.8—10.8 2
{80—110,
70—95}

N·m {kgf·cm, in·lbf}

ac9uuw00000001

01-13–8
1890-1U-06H(01-14).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

01-14 FUEL SYSTEM [MZI-3.5]
FUEL SYSTEM LOCATION FUEL PUMP UNIT INSPECTION
INDEX [MZI-3.5] . . . . . . . . . . . . . . . . . . 01-14–2 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-14–19
Engine Compartment Side. . . . . . . . . . 01-14–2 Operation Test . . . . . . . . . . . . . . . . . . . . 01-14–19
Fuel Tank Side . . . . . . . . . . . . . . . . . . . 01-14–3 Continuity Inspection. . . . . . . . . . . . . . . 01-14–21
FUEL SYSTEM DIAGRAM Circuit Open/Short Inspection . . . . . . . . 01-14–21
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-14–4 QUICK RELEASE CONNECTOR 01-14
BEFORE REPAIR PROCEDURE (FUEL SYSTEM)
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-14–5 REMOVAL/INSTALLATION
Fuel Line Safety Procedure . . . . . . . . . 01-14–5 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-14–22
AFTER REPAIR PROCEDURE Quick Release
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-14–5 Connector Position . . . . . . . . . . . . . . . 01-14–22
Fuel Leakage Inspection . . . . . . . . . . . 01-14–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-14–22
FUEL LINE PRESSURE INSPECTION Installation . . . . . . . . . . . . . . . . . . . . . . . 01-14–22
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-14–6 FUEL INJECTOR
FUEL TANK REMOVAL/INSTALLATION REMOVAL/INSTALLATION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-14–8 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-14–23
2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14–8 Fuel Injector Removal Note. . . . . . . . . . 01-14–24
AWD. . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14–11 Fuel Injector Installation Note . . . . . . . . 01-14–25
FUEL TANK INSPECTION FUEL INJECTOR INSPECTION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-14–14 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-14–25
NONRETURN VALVE INSPECTION Operation Test . . . . . . . . . . . . . . . . . . . . 01-14–25
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-14–16 Resistance Inspection . . . . . . . . . . . . . . 01-14–25
FUEL PUMP UNIT Circuit Open/Short Inspection . . . . . . . . 01-14–26
REMOVAL/INSTALLATION Atomization . . . . . . . . . . . . . . . . . . . . . . 01-14–27
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-14–16 PRESSURE REGULATOR
FUEL PUMP UNIT INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-14–27
DISASSEMBLY/ASSEMBLY
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-14–19

End of Toc
WM: FUEL SYSTEM

01-14–1
1890-1U-06H(01-14).fm 2 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

FUEL SYSTEM LOCATION INDEX [MZI-3.5]
id0114d1800100
Engine Compartment Side

FRONT

ac9uuw00000128
.

1 Fuel injector 2 Quick release connector

(See 01-14-23 FUEL INJECTOR REMOVAL/ (See 01-14-22 QUICK RELEASE CONNECTOR
INSTALLATION [MZI-3.5].) (FUEL SYSTEM) REMOVAL/INSTALLATION [MZI-
(See 01-14-25 FUEL INJECTOR INSPECTION 3.5].)
[MZI-3.5].) 3 Fuel pump relay
(See 09-21-6 RELAY INSPECTION.)
4 Schrader valve

01-14–2
1890-1U-06H(01-14).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

Fuel Tank Side
2WD

01-14

ac9uuw00000073

AWD

ac9uuw00000176

1 Fuel tank 2 Nonreturn valve

(See 01-14-8 FUEL TANK REMOVAL/ (See 01-14-16 NONRETURN VALVE INSPECTION
INSTALLATION [MZI-3.5].) [MZI-3.5].)
(See 01-14-14 FUEL TANK INSPECTION [MZI-
3.5].)

01-14–3
1890-1U-06H(01-14).fm 4 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

3 Fuel pump unit 4 Quick release connector
(See 01-14-16 FUEL PUMP UNIT REMOVAL/ (See 01-14-22 QUICK RELEASE CONNECTOR
INSTALLATION [MZI-3.5].) (FUEL SYSTEM) REMOVAL/INSTALLATION [MZI-
(See 01-14-19 FUEL PUMP UNIT DISASSEMBLY/ 3.5].)
ASSEMBLY [MZI-3.5].)
(See 01-14-19 FUEL PUMP UNIT INSPECTION
[MZI-3.5].)

End Of Sie
FUEL SYSTEM DIAGRAM [MZI-3.5]
id0114d1800200

FUEL INJECTOR
PRESSURE
REGULATOR

FUEL TANK

FUEL FILTER (HIGH

PRESSURE)

: TO PCM

2WD AWD

FUEL TANK FUEL FLOW

FUEL PUMP UNIT

FUEL FILTER (LOW PRESSURE)

ac9uuw00000180

End Of Sie

01-14–4
1890-1U-06H(01-14).fm 5 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

BEFORE REPAIR PROCEDURE [MZI-3.5]
id0114d1800300

Warning
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel
Line Safety Procedure”. 01-14
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before performing work on the fuel system, discharge static electricity by touching
the vehicle body.

Fuel Line Safety Procedure

Note
• Fuel in the fuel system is under high pressure also when the engine is not running.
1. Remove the fuel-filler cap and release the pressure in the fuel tank.
2. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the fuel pump relay.
4. Connect the negative battery cable. (See 01-17-2
BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
5. Start the engine.
6. After the engine stalls, crank the engine several
times.
7. Turn the ignition switch to LOCK position. FUEL PUMP RELAY
8. Install the fuel pump relay.
End Of Sie

MAIN FUSE BLOCK

ac9uuw00000129

AFTER REPAIR PROCEDURE [MZI-3.5]

id0114d1800400

Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. When installing the fuel hose, observe “Fuel Leakage Inspection” described below.

Fuel Leakage Inspection

Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Always carry out the following procedure with the engine stopped.

Using M-MDS
1. Connect the M-MDS to the DLC-2.
2. Using the simulation function “FP”, start the fuel
pump.
3. Verify that there is no fuel leakage from the
pressurized parts.
• If there is leakage, replace the fuel hoses and
clips.
• If there is damage on the seal on the fuel pipe
side, replace the fuel pipe. DLC-2

Standard
There shall be no leakage after 5 min.
ac9uuw00000119
4. After reinstallation, repeat step 2—3 in the fuel
leakage inspection.

01-14–5
1890-1U-06H(01-14).fm 6 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

Without using M-MDS
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5])
2. Remove the fuel pump relay.

Caution
• Short the specified terminals because shorting the wrong terminal of the main fuse block may
cause malfunctions.

3. Using a jumper wire, short fuel pump relay

MAIN FUSE BLOCK
terminals C and D in the main fuse block.
(FUEL PUMP RELAY)
4. Connect the negative battery cable and operate
the fuel pump. A E
5. Verify that there is no fuel leakage from the
pressurized parts. C
• If there is leakage, replace the fuel hoses and
D
clips.
• If there is damage on the seal on the fuel pipe
side, replace the fuel pipe.

Standard
ac9uuw00001018
There shall be no leakage after 5 min.

6. After repair, assemble the system and repeat Steps 4—5.

End Of Sie
FUEL LINE PRESSURE INSPECTION [MZI-3.5]
id0114d1800500

Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death.
Fuel can also irritate skin and eyes. To prevent this, always complete the “BEFORE REPAIR
PROCEDURE”.

1. Complete the “BEFORE REPAIR PROCEDURE”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
2. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the fuel line schrader valve cap.

SCHRADER VALVE CAP

FUEL DISTRIBUTOR

ac9uuw00002152

01-14–6
1890-1U-06H(01-14).fm 7 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

4. Turn the SST lever so that it is 90° to the hose as
shown in the figure.
5. Make sure the lever of fuel pressure gauge is 49 B019 901B
turned fully clockwise, then connect the SST to
the schrader valve.
6. Verify that the selector is in N position.
49 N013 101A
01-14
LEVER

49 T013 101

ac9uuw00002400

7. Start the fuel pump using the following procedure.

Using M-MDS
1. Connect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Connect the M-MDS to the DLC-2.
3. Using the simulation function “FP”, start the
fuel pump.
Without using M-MDS
1. Remove the fuel pump relay.

Caution
• Short the specified terminals because
shorting the wrong terminal of the main DLC-2
fuse block may cause malfunctions.

ac9uuw00000115

2. Using a jumper wire, short fuel pump relay

MAIN FUSE BLOCK
terminals C and D in the main fuse block.
(FUEL PUMP RELAY)
3. Connect the negative battery cable and
operate the fuel pump. A E
8. Measure the fuel line pressure. (during key on
engine off (KOEO)) C
• If not as specified, inspect the following:
D
Zero or low
— FP circuit
— FP
— Fuel line (clogging)
— Fuel leakage inside pressure regulator
ac9uuw00001018
High
— Pressure regulator

Fuel line pressure

331—485 kPa {3.38—4.94 kgf/cm2, 48.1—70.3 psi}

9. Stop the fuel pump using the following procedure.

Using M-MDS
1. Stop the fuel pump using the “FP” simulation function.
Using M-MDS
1. Turn the ignition switch off.
2. Disconnect the negative battery cable to stop the fuel pump.
10. Disconnect the fuel pressure gauge and connect the fuel pipe.
11. Complete the “AFTER REPAIR PROCEDURE”. (See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)
End Of Sie
WM: FUEL TANK

01-14–7
1890-1U-06H(01-14).fm 8 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

FUEL TANK REMOVAL/INSTALLATION [MZI-3.5]
id0114d1801600

Warning
• Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before draining fuel, make sure to discharge static electricity by touching the
vehicle body.

Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.

2WD
1. Level the vehicle.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
3. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove the fuel line schrader valve cap.
6. Connect a long hose to the disconnected
schrader valve cap and drain the fuel into a SCHRADER VALVE CAP
container used for collecting gasoline.

FUEL DISTRIBUTOR

ac9uuw00002153

7. Start the fuel pump using the following procedure.

Using M-MDS
1. Connect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Connect the M-MDS to the DLC-2.
3. Using the simulation function FP, start the fuel
pump.
Without using M-MDS
1. Remove the fuel pump relay.

Caution
• Short the specified terminals because
shorting the wrong terminal of the main DLC-2
fuse block may cause malfunctions.

ac9uuw00000114

01-14–8
1890-1U-06H(01-14).fm 9 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

2. Using a jumper wire, short fuel pump relay
MAIN FUSE BLOCK
terminals C and D in the main fuse block.
(FUEL PUMP RELAY)
3. Connect the negative battery cable and
operate the fuel pump. A E

Caution C
• The fuel pump could be damaged if it is
D
operated (fuel pump idling) while there is 01-14
no fuel in the fuel tank. Verify the amount
of fuel being discharged from the hose
and stop operation of the fuel pump
when essentially no fuel is being
ac9uuw00001018
discharged.

8. When essentially no fuel is being discharged, stop the fuel pump.

9. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
10. Remove the presilencer. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
11. To remove the fuel pump unit, remove the following parts:
(1) Second-row seat (LH) (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
(2) Edge cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(3) Long slider cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(4) Rear heat duct No.3 (See 07-11-11 REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION.)
(5) Fuel pump unit (See 01-14-16 FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.5].)
12. Siphon the fuel from the fuel tank.
13. Remove in the order indicated in the table.
14. Install in the reverse order of removal.
15. Complete the “AFTER REPAIR PROCEDURE”. (See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

01-14–9
1890-1U-06H(01-14).fm 10 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

8
21.6—30.4
{2.21—3.09,
4 16.0—22.4}
7

21.6—30.4 1
{2.21—3.09, 3
16.0—22.4}
8.8—12.7 N·m
{89.8—129 kgf·cm,
2 77.9—112 in·lbf}

21.6—30.4
{2.21—3.09,
16.0—22.4}

4
21.6—30.4 22.0—30.0
{2.21—3.09, {2.25—3.05, 22.0—30.0
16.0—22.4} 16.3—22.1} {2.25—3.05,
21.6—30.4
{2.21—3.09, 16.3—22.1}
21.6—30.4
{2.21—3.09, 16.0—22.4}
16.0—22.4}

N·m {kgf·m, ft·lbf}

ac9uuw00000184

1 Joint hose 6 Fuel-filler cap

2 Evaporative hose component 7 Fuel-filler pipe protector
3 Fuel tank (See 01-14-10 Fuel-filler pipe protector removal
note.)
4 Fuel tank bracket
8 Fuel-filler pipe
5 Fuel tank insulator (See 01-14-11 Fuel-filler pipe removal note.)

Fuel-filler pipe protector removal note

1. Remove the rear tire (LH).
2. Remove the splash shield (LH).
3. Remove the fuel-filler pipe protector.

01-14–10
1890-1U-06H(01-14).fm 11 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

Fuel-filler pipe removal note
1. Remove the rear tire (RH).
2. Remove the spare tire.
3. Remove the main silencer (LH). (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the main silencer insulator (LH).
5. To lower the rear crossmember, perform the following procedure:
(1) Set the rear ABS wheel-speed sensor out of the way. (See 04-18-13 REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [2WD].) 01-14
(2) Rear coil spring (See 02-14-5 REAR COIL SPRING REMOVAL/INSTALLATION.)
(3) Lowered the rear crossmember. (See 02-14-22 REAR CROSSMEMBER REMOVAL/INSTALLATION
[2WD].)
6. Remove the fuel-filler pipe.
AWD
1. Level the vehicle.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
3. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove the fuel line schrader valve cap.
6. Connect a long hose to the disconnected
schrader valve cap and drain the fuel into a SCHRADER VALVE CAP
container used for collecting gasoline.

FUEL DISTRIBUTOR

ac9uuw00002153

7. Start the fuel pump using the following procedure.

Using M-MDS
1. Connect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Connect the M-MDS to the DLC-2.
3. Using the simulation function FP, start the fuel
pump.
Without using M-MDS
1. Remove the fuel pump relay.

Caution
• Short the specified terminals because
shorting the wrong terminal of the main DLC-2
fuse block may cause malfunctions.

ac9uuw00000114

2. Using a jumper wire, short fuel pump relay

MAIN FUSE BLOCK
terminals C and D in the main fuse block.
(FUEL PUMP RELAY)
3. Connect the negative battery cable and
operate the fuel pump. A E

Caution C
• The fuel pump could be damaged if it is
D
operated (fuel pump idling) while there is
no fuel in the fuel tank. Verify the amount
of fuel being discharged from the hose
and stop operation of the fuel pump
when essentially no fuel is being
ac9uuw00001018
discharged.
01-14–11
1890-1U-06H(01-14).fm 12 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

8. When essentially no fuel is being discharged, stop the fuel pump.
9. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
10. To remove the propeller shaft, remove the following parts:
(1) Presilencer (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
(2) Presilencer insulator
(3) Propeller shaft (See 03-15-2 PROPELLER
SHAFT REMOVAL/INSTALLATION.)
PRESILENCER
11. To remove the fuel pump unit, remove the INSULATOR
following parts:
(1) Second-row seat (LH) (See 09-13-19
SECOND-ROW SEAT REMOVAL/
INSTALLATION.)
(2) Edge cover (See 09-13-22 LONG SLIDER 8—10
{82—101,
REMOVAL/INSTALLATION.) 71—88}
8—10
(3) Long slider cover (See 09-13-22 LONG {82—101, 71—88} N·m {kgf·cm, ft·lbf}
SLIDER REMOVAL/INSTALLATION.)
ac9uuw00001381
(4) Rear heat duct No.3 (See 07-11-11 REAR
HEAT DUCT COMPONENT REMOVAL/
INSTALLATION.)
(5) Fuel pump unit (See 01-14-16 FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.5].)
12. Siphon the fuel from the fuel tank.
13. Remove in the order indicated in the table.
14. Install in the reverse order of removal.
15. Complete the “AFTER REPAIR PROCEDURE”. (See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

01-14–12
1890-1U-06H(01-14).fm 13 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

10

21.6—30.4 01-14
{2.21—3.09,
5 16.0—22.4}

21.6—30.4 1
{2.21—3.09, 4 9
16.0—22.4}
8.8—12.7 N·m
{89.8—129 kgf·cm,
2 77.9—112 in·lbf}

21.6—30.4
{2.21—3.09,
16.0—22.4}

5
22.0—30.0
{2.25—3.05, 22.0—30.0
16.3—22.1} 21.6—30.4 {2.25—3.05,
{2.21—3.09, 16.3—22.1}
21.6—30.4
{2.21—3.09, 16.0—22.4}
16.0—22.4}

43.1—60.8
{4.40—6.19,
31.8—44.8} 3

43.1—60.8
{4.40—6.19,
31.8—44.8} 7 6 43.1—60.8
N·m {kgf·m, ft·lbf}
{4.40—6.19,
31.8—44.8}

ac9uuw00002427

1 Joint hose 7 Fuel tank insulator No.2

2 Evaporative hose 8 Fuel-filler cap
3 Protector 9 Fuel-filler pipe protector
4 Fuel tank (See 01-14-13 Fuel-filler pipe protector removal
note.)
5 Fuel tank bracket
10 Fuel-filler pipe
6 Fuel tank insulator No.1 (See 01-14-14 Fuel-filler pipe removal note.)

Fuel-filler pipe protector removal note

1. Remove the rear tire (LH).
2. Remove the splash shield (LH).
3. Remove the fuel-filler pipe protector.

01-14–13
1890-1U-06H(01-14).fm 14 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

Fuel-filler pipe removal note
1. Remove the rear tire (RH).
2. Remove the spare tire.
3. Remove the main silencer (LH). (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the main silencer insulator (LH).
5. To lower the rear crossmember, perform the following procedure:
(1) Set the rear ABS wheel-speed sensor out of the way. (See 04-18-14 REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [AWD].)
(2) Rear coil spring (See 02-14-5 REAR COIL SPRING REMOVAL/INSTALLATION.)
(3) Lowered the rear crossmember. (See 02-14-24 REAR CROSSMEMBER REMOVAL/INSTALLATION
[AWD].)
6. Remove the fuel-filler pipe.
End Of Sie
FUEL TANK INSPECTION [MZI-3.5]
id0114d1803200

Note
• This inspection is for three rollover valves and fuel shut-off valve integrated in the fuel tank.

1. Follow “BEFORE SERVICE PRECAUTION” before performing any work operations to prevent fuel from spilling
from the fuel system. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
2. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
3. To disconnect the fuel pump unit connector, remove the following parts:
(1) Second-row seat (LH) (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
(2) Edge cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(3) Long slider cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(4) Rear heat duct No.3 (See 07-11-11 REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION.)
(5) Disconnect the fuel pump unit connector.
4. Disconnect the quick release connector and the fuel pump unit connector. (See 01-14-22 QUICK RELEASE
CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [MZI-3.5].)
5. Disconnect the joint hose. (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-3.5].)
6. Disconnect the evaporative hose. (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-3.5].)
7. Remove the fuel tank with the fuel pump unit. (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-3.5].)
8. Perform the following procedure to verify the fuel tank airtightness.
(1) Plug the fuel pump unit pipe and port B.
2WD

A
B

PLUG

PLUG

FUEL PUMP UNIT

ac9uuw00000131

01-14–14
1890-1U-06H(01-14).fm 15 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

AWD
(2) Apply a pressure of 3 kPa {23 mmHg, 0.9 A
inHg} to port A and wait for a while.
B
(3) Verify that there is no air leakage from the fuel
tank. PLUG
• If there is airflow, replace the fuel tank.
9. Level the fuel tank.
10. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} PLUG 01-14
to port B and wait for a while.
11. With the pressure still applied, verify that there is
airflow from port A and the pressure is 0—3 kPa FUEL PUMP UNIT
{0—22 mmHg, 0—0.8 inHg}.
• If malfunction, replace the fuel tank. ac9uuw00000177
12. Apply a pressure of –0.5 kPa {–3.8 mmHg, –0.1
inHg} to port B and wait for a while.
13. With the pressure still applied, verify that there is airflow from port A and the pressure is –0.5—0 kPa {–3.8—0
mmHg, –0.2—0 inHg}.
• If malfunction, replace the fuel tank.
• If there is airflow, place the fuel tank upside down.
14. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port B and wait for a while.
2WD

FUEL PUMP UNIT

PLUG

B
A

ac9uuw00000132

AWD
15. With the pressure still applied, verify that there is
no airflow from port A.
FUEL PUMP UNIT
• If there is airflow, replace the fuel tank.
16. Complete the “AFTER REPAIR PROCEDURE”.
(See 01-02-8 AFTER REPAIR PROCEDURE PLUG
[MZI-3.5].)
End Of Sie
WM: NONRETURN VALVE

B
A

ac9uuw00002430

01-14–15
1890-1U-06H(01-14).fm 16 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

NONRETURN VALVE INSPECTION [MZI-3.5]
id0114d1803600

Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause
serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this,
always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE
PRECAUTION”.

1. Follow “BEFORE SERVICE PRECAUTION” before performing any work operations to prevent fuel from spilling
from the fuel system. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
2. Disconnect the negative battery cable.
3. Remove the fuel pump unit. (See 01-14-16 FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.5].)
4. Siphon the fuel from the fuel tank.

Note
• Nonreturn valve is integrated in the fuel tank.
• The nonreturn valve is normally closed by the spring force.
• Verify the nonreturn valve operation using a mirror.

5. Verify that the nonreturn valve is closed.

• If malfunction, replace the fuel tank. (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-3.5].)
6. Verify that the nonreturn valve is not stuck open
and does not open even when pulled up by a
finger.
• If malfunction, replace the fuel tank. (See 01-
14-8 FUEL TANK REMOVAL/INSTALLATION
[MZI-3.5].)
End Of Sie
WM: FUEL PUMP

NONRETURN VALVE

ac9uuw00002456

FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.5]

id0114d1800900

Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit
removal/installation, always complete the “Fuel Leak Inspection After Fuel Pump Unit
Installation”.
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before draining fuel, make sure to discharge static electricity by touching the
vehicle body.

Caution
• Because the fuel tank is constructed such that the fuel level is higher than the installation surface
of the fuel pump, fuel leakage could occur. If the fuel gauge indicates a fuel level of 3/4 or more,
perform the following Steps 3—8 to drain 10—15 L {2.7—3.9 US gal, 2.2—3.2 lmp gal} of fuel.
• Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.

1. Level the vehicle.

2. Complete the “BEFORE REPAIR PROCEDURE”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
3. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)

01-14–16
1890-1U-06H(01-14).fm 17 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

5. Remove the fuel line schrader valve cap.
6. Connect a long hose to the disconnected
schrader valve cap and drain the fuel into a SCHRADER VALVE
container used for collecting gasoline.
7. Start the fuel pump using the following procedure.
Using M-MDS
1. Connect the negative battery cable. (See 01-
17-2 BATTERY REMOVAL/INSTALLATION 01-14
[MZI-3.5].)

FUEL DISTRIBUTOR

ac9uuw00000425

2. Connect the M-MDS to the DLC-2.

3. Using the simulation function “FP”, start the
fuel pump.

DLC-2

ac9uuw00000115

Without using M-MDS

1. Remove the fuel pump relay.

Caution
• Short the specified terminals because shorting the wrong terminal of the main fuse block may
cause malfunctions.

2. Using a jumper wire, short fuel pump relay

MAIN FUSE BLOCK
terminals C and D in the main fuse block.
(FUEL PUMP RELAY)
3. Connect the negative battery cable and
operate the fuel pump. A E

Caution C
• The fuel pump could be damaged if it is
D
operated (fuel pump idling) while there is
no fuel in the fuel tank. Verify the amount
of fuel being discharged from the hose
and stop operation of the fuel pump
when essentially no fuel is being
ac9uuw00001018
discharged.

8. When essentially no fuel is being discharged, stop operation of the fuel pump.
9. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
10. To remove the rear heat duct No.3, remove the following parts:
(1) Second-row seat (LH) (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
(2) Edge cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(3) Long slider cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(4) Remove the rear heat duct No.3. (See 07-11-11 REAR HEAT DUCT COMPONENT REMOVAL/
INSTALLATION.)
11. Remove in the order indicated in the table.
12. Install in the reverse order of removal.
13. Complete the “AFTER REPAIR PROCEDURE”. (See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

01-14–17
1890-1U-06H(01-14).fm 18 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

2WD
.

1 Service hole cover 1.5—2.6 N·m {16—26 kgf·cm, 14—23 in·lbf}

2 Connector
1
3 Quick release connector
(See 01-14-22 QUICK RELEASE CONNECTOR 2 R
(FUEL SYSTEM) REMOVAL/INSTALLATION [MZI-
3.5].) 5
4 Fuel pump unit
3
5 Packing

ac9uuw00002431

AWD
.

1 Service hole cover 1.5—2.6 N·m {16—26 kgf·cm, 14—23 in·lbf}

2 Connector 1
3 Quick release connector
(See 01-14-22 QUICK RELEASE CONNECTOR 2
(FUEL SYSTEM) REMOVAL/INSTALLATION [MZI- R
3.5].) 6
4 Quick release connector
(See 01-14-22 QUICK RELEASE CONNECTOR 3
(FUEL SYSTEM) REMOVAL/INSTALLATION [MZI-
3.5].)
5 Fuel pump unit 5
6 Packing 4
End Of Sie

ac9uuw00001187

01-14–18
1890-1U-06H(01-14).fm 19 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY [MZI-3.5]
id0114d1801000
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.

1 Fuel filter body

2 Pressure regulator
3 O-ring
4 Fuel pump 01-14
1
5 O-ring R
6 Spacer
7 Fuel filter (low-pressure)
8 Sender gauge
R 3
End Of Sie 5 R
OIL 2
6

ac9uuw00000273

FUEL PUMP UNIT INSPECTION [MZI-3.5]

id0114d1801100

Caution
• It is normal to hear the fuel pump operating when the ignition switch is turned to the ON position.

Note
• To improve start ability, the fuel pump control operates the fuel pump unit when the ignition switch is
turned to the ON position. Due to this, fuel pressure is rapidly increased and fuel control is stabilized.

Operation Test
1. Follow “BEFORE SERVICE PRECAUTION” before performing any work operations to prevent fuel from spilling
from the fuel system. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
2. Remove the fuel-filler cap. (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-3.5].)
3. Start the fuel pump using the following procedure:

Using M-MDS
1. Connect the M-MDS to the DLC-2.
2. Turn the ignition switch to the ON position.

DLC-2

ac9uuw00000116

01-14–19
1890-1U-06H(01-14).fm 20 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

3. Using the simulation function FP, verify that operation sound is heard from the fuel pump when FP is turned
from OFF to ON.
• If the operation sound cannot be verified,
measure the voltage at fuel pump wiring FUEL PUMP UNIT
harness-side connector terminal B. WIRING HARNESS-SIDE CONNECTOR
— If as specified, inspect the following:
• Fuel pump continuity
— If not within the specification, inspect the C A
following: D B
• Fuel pump relay
• Wiring harnesses and connectors
between battery—fuel pump relay—
fuel pump
ac9uuw00001003
Standard
B+ (Ignition switch at ON)

Without using M-MDS

1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the fuel pump relay.

Caution
• Short the specified terminals because shorting the wrong terminal of the main fuse block may
cause malfunctions.

3. Using a jumper wire, short fuel pump relay

MAIN FUSE BLOCK
terminals C and D in the main fuse block.
(FUEL PUMP RELAY)
4. Connect the negative battery cable and operate
the fuel pump. A E

ac9uuw00001018

5. Verify that operation sound is heard from the fuel pump when ignition switch turn to the ON position.
• If the operation sound cannot be verified,
measure the voltage at fuel pump wiring FUEL PUMP UNIT
harness-side connector terminal B. WIRING HARNESS-SIDE CONNECTOR
— If as specified, inspect the following:
• Fuel pump continuity
— If not within the specification, inspect the C A
following: D B
• Fuel pump relay
• Wiring harnesses and connectors
between battery—fuel pump relay—
fuel pump
ac9uuw00001003
Standard
B+ (Ignition switch at ON)

6. Disconnect the jumper wire.

4. Complete the “AFTER REPAIR PROCEDURE”. (See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

01-14–20
1890-1U-06H(01-14).fm 21 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

Continuity Inspection
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. To remove the service hole cover, remove the following parts:
(1) Second-row seat (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
(2) Edge cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(3) Long slider cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(4) Rear heat duct No.3 (See 07-11-11 REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION.)
(5) Service hole cover (See 01-14-16 FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.5].) 01-14
3. Disconnect the fuel pump unit connector.
4. Inspect for continuity between fuel pump unit
connector terminals B and D. FUEL PUMP UNIT
• If there is no continuity, replace the fuel pump WIRING HARNESS-SIDE CONNECTOR
unit. (See 01-14-16 FUEL PUMP UNIT
REMOVAL/INSTALLATION [MZI-3.5].)
• If as specified carry out the “Circuit Open/ C A
Short Inspection”. D B

ac9uuw00001003

Circuit Open/Short Inspection

1. Inspect the following wiring harnesses for open or
MAIN FUSE BLOCK
short circuit (continuity check).
(FUEL PUMP RELAY)

A E

ac9uuw00001018

FUEL PUMP UNIT

WIRING HARNESS-SIDE CONNECTOR

C A
D B

ac9uuw00001003

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
— Fuel pump unit terminal D and body ground
— Fuel pump unit terminal C and fuel pump relay terminal D

Short circuit
• If there is continuity, the circuit is short. Repair or replace the harness.
— Fuel pump unit terminal D and power supply
— Fuel pump unit terminal B and body ground
End Of Sie
WM: QUICK RELEASE CONNECTOR

01-14–21
1890-1U-06H(01-14).fm 22 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [MZI-3.5]
id0114d1804800

Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause
serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this,
always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE
PRECAUTION”.

Quick Release Connector Position

FUEL TANK ENGINE

SIDE COMPARTMENT SIDE

QUICK RELEASE CONNECTOR

2WD AWD

QUICK RELEASE CONNECTOR

ac9uuw00000181
Removal
1. Follow “BEFORE REPAIR PROCEDURE” and remove dirt from the connecting surfaces before performing any
work operations. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
2. Move the retainer upward using a small flathead
screwdriver or a similar tool. FLATHEAD
SCREWDRIVER RETAINER
3. Pull out the fuel hose straight from the fuel pipe
and disconnect it.
4. Cover the disconnected quick release connector
and fuel pipe with vinyl sheeting or a similar
material to prevent it from scratches or dirt.

QUICK RELEASE
CONNECTOR
acxuuw00000059
Installation

Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
• If there is any malfunction, replace it with a new one.
2. Install the quick release connector.
• Insert the fuel pipe straight to the end of the
quick release connector. 2
• Push down the retainer using a finger.
— If the retainer cannot be pushed down,
push the fuel pipe further to the quick
release connector.
1
3. Lightly pull and push the quick release connector
a few times by hand, and then verify that it is
connected securely.
4. Inspect all related parts by performing “AFTER
REPAIR PROCEDURE”. (See 01-14-5 AFTER
acxuuw00000061
REPAIR PROCEDURE [MZI-3.5].)
End Of Sie

01-14–22
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FUEL SYSTEM [MZI-3.5]

FUEL INJECTOR REMOVAL/INSTALLATION [MZI-3.5]
WM: FUEL INJECTOR

id0114d1800600

Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause
serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this,
always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE
PRECAUTION”.
01-14
1. Complete the “BEFORE REPAIR PROCEDURE”. (See 01-14-5 BEFORE REPAIR PROCEDURE [MZI-3.5].)
2. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the dynamic chamber (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove in the order indicated in the table.
8.5—11.5 {87—117, 76—101}

8.5—11.5 {87—117, 76—101}

SCHRADER
VALVE 4
2
1

OIL
R
7 3
3 7
6

5 5
6 7
7 R OIL

N·m {kgf·cm, in·lbf}

ac9uuw00000320

1 Quick release connector 5 Clip

(See 01-14-22 QUICK RELEASE CONNECTOR 6 Fuel injector
(FUEL SYSTEM) REMOVAL/INSTALLATION [MZI- (See 01-14-24 Fuel Injector Removal Note.)
3.5].) (See 01-14-25 Fuel Injector Installation Note.)
2 Wiring harness retainer 7 O-ring
3 Fuel injector connectors
4 Fuel distributor

6. Install in the reverse order of removal.

7. Complete the “AFTER REPAIR PROCEDURE”. (See 01-14-5 AFTER REPAIR PROCEDURE [MZI-3.5].)

01-14–23
1890-1U-06H(01-14).fm 24 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

Fuel Injector Removal Note

Caution
• Use of a deformed injector retaining clip will cause the injector to not engage correctly. Always
use a new clip when reattaching the injector, otherwise it may cause the injector to rotate.

1. Insert a screwdriver between the injector cup and

the clip fingers. INSERT
SCREWDRIVER
INJECTOR CUP

ROTATE AND
SPREAD

CLIP FINGER

CLIP

ac9uuw00001305

Note
• When rotating the screwdriver to spread the
clip fingers, deform them sufficiently to make
sure they release from the notched edge of
the injector cup.
CLIP FINGER
2. Rotate the screwdriver to spread the clip fingers
and remove them from the injector cup. NOTCH
3. Pull the injector and clip out of the rail.

ac9uuw00001306

4. Remove the clip from the injector according to the following:

(1) Grasp the clip with a pair of pliers.
(2) Pull the clip parallel to the injector groove, and
remove it from the injector.
(3) Discard the clip. PULL OUT PARALLEL

INJECTOR GROOVE

ac9uuw00001307

01-14–24
1890-1U-06H(01-14).fm 25 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

Fuel Injector Installation Note
1. Install the new O-ring.
2. Lightly lubricate the injector groove and O-ring.
3. Pre-attach a new clip in the injector groove.

Note
• When the clip is attached correctly, the central area of the injector and the clip finger positions are aligned.
01-14
4. Hold the injector firmly, push the clip into the
injector until the clip stops sliding.
5. Verify that the injector connector position is
correct, and press the injector and clip into the
injector cup. Continue pressing until the clip PRESS IN
contacts the lower surface of the injector cup.
6. Verify that the injector and clip are correctly
attached with the clip locked onto the injector cup
notch.
End Of Sie

ac9uuw00001308

FUEL INJECTOR INSPECTION [MZI-3.5]

id0114d1800700

Note
• Perform the following inspection only when directed.

Operation Test
1. Carry out the “Fuel Injector Operation Inspection”. (See 01-03-60 ENGINE CONTROL SYSTEM OPERATION
INSPECTION [MZI-3.5].)
• If not as specified, perform the further inspection for the fuel injectors.

Resistance Inspection
1. Turn the ignition switch to LOCK position.
2. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the dynamic chamber. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
5. Disconnect the fuel injector connectors.
6. Measure the resistance of the fuel injector.
• If not as specified, replace the fuel injector.
(See 01-14-23 FUEL INJECTOR REMOVAL/
A
INSTALLATION [MZI-3.5].)
• If as specified but “Operation Test” is failed, B
carry out the “Circuit Open/Short Inspection”.
Inspect for open or short circuit.

Fuel injector resistance

11—18 ohms

ac9uuw00001004

01-14–25
1890-1U-06H(01-14).fm 26 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

Circuit Open/Short Inspection
1. Disconnect the PCM connector.
2. Inspect the following wiring harness for open or
short (continuity check). FUEL INJECTOR
WIRING HARNESS-SIDE CONNECTOR

ac9uuw00001005

MAIN FUSE BLOCK

(FUEL PUMP RELAY)

A E

ac9uuw00001018

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00001006

01-14–26
1890-1U-06H(01-14).fm 27 ページ ２００６年１２月１９日　火曜日　午前１０時４３分

FUEL SYSTEM [MZI-3.5]

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
— No.1 cylinder fuel injector terminal A and PCM terminal 2BJ
— No.2 cylinder fuel injector terminal A and PCM terminal 2BM
— No.3 cylinder fuel injector terminal A and PCM terminal 2BF
— No.4 cylinder fuel injector terminal A and PCM terminal 2BH
— No.5 cylinder fuel injector terminal A and PCM terminal 2BB
— No.6 cylinder fuel injector terminal A and PCM terminal 2BD 01-14
— No.1 cylinder fuel injector terminal B and fuel pump relay terminal D
— No.2 cylinder fuel injector terminal B and fuel pump relay terminal D
— No.3 cylinder fuel injector terminal B and fuel pump relay terminal D
— No.4 cylinder fuel injector terminal B and fuel pump relay terminal D
— No.5 cylinder fuel injector terminal B and fuel pump relay terminal D
— No.6 cylinder fuel injector terminal B and fuel pump relay terminal D

Short circuit
• If there is continuity, the circuit is short. Repair or replace the harness.
— No.1 cylinder fuel injector terminal A and body ground
— No.2 cylinder fuel injector terminal A and body ground
— No.3 cylinder fuel injector terminal A and body ground
— No.4 cylinder fuel injector terminal A and body ground
— No.5 cylinder fuel injector terminal A and body ground
— No.6 cylinder fuel injector terminal A and body ground
— No.1 cylinder fuel injector terminal B and power supply
— No.2 cylinder fuel injector terminal B and power supply
— No.3 cylinder fuel injector terminal B and power supply
— No.4 cylinder fuel injector terminal B and power supply
— No.5 cylinder fuel injector terminal B and power supply
— No.6 cylinder fuel injector terminal B and power supply

Atomization
1. Inspect atomization pattern.
• If the atomization is faulty, replace the fuel
injector. (See 01-14-23 FUEL INJECTOR
REMOVAL/INSTALLATION [MZI-3.5].)
End Of Sie
WM: PRESSURE REGULATOR

NORMAL FAULTY ATOMIZATION

am8rrw00001725

PRESSURE REGULATOR INSPECTION [MZI-3.5]

id0114d1800800

Note
• Due to the adoption of the mechanical returnless fuel system, the pressure regulator cannot be inspected
separately.

1. Perform “FUEL LINE PRESSURE INSPECTION”. (See 01-14-6 FUEL LINE PRESSURE INSPECTION [MZI-
3.5].)
End Of Sie

01-14–27
1890-1U-06H(01-15).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時４７分

EXHAUST SYSTEM [MZI-3.5]

01-15 EXHAUST SYSTEM [MZI-3.5]
EXHAUST SYSTEM INSPECTION Exhaust Manifold Insulator (LH)
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-15–1 Removal Note . . . . . . . . . . . . . . . . . . . 01-15–3
EXHAUST SYSTEM Warm Up Three Way Catalytic
REMOVAL/INSTALLATION Converter (WU-TWC) (LH)
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-15–1 Installation Note . . . . . . . . . . . . . . . . . 01-15–3
Warm Up Three Way Catalytic Warm Up Three Way Catalytic 01-15
Converter (WU-TWC) (RH) Converter (WU-TWC) (RH)
Removal Note . . . . . . . . . . . . . . . . . . 01-15–3 Installation Note . . . . . . . . . . . . . . . . . 01-15–3

End of Toc
EXHAUST SYSTEM INSPECTION [MZI-3.5]
WM: EXHAUST SYSTEM

id0115d1800100
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
• If leakage is found, repair or replace as necessary.
End Of Sie
EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5]
id0115d1800200

Warning
• When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the exhaust system.

1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

01-15–1
1890-1U-06H(01-15).fm 2 ページ ２００６年１２月１９日　火曜日　午前１０時４７分

EXHAUST SYSTEM [MZI-3.5]

21.2—28.8
17—23 {2.17—2.93 ,
{1.8—2.3, 15.7—21.2}
13—16} 12
SST
21.2—28.8 40.3—54.7 {4.11—5.57, 29.8—40.3}
{2.17—2.93 ,
15.7—21.2} R
14
17—23
{1.8—2.3 , SST 16
13—16} 17—23
40.3—54.7
17 {1.8—2.3,
{4.11—5.57, R
13—16}
29.8—40.3}
R
15 8
10 A

13
R
17—23
{1.8—2.3, 6 34—46
SST 13—16} {3.5—4.6 , R
40.3—54.7 26—33}
34—46
9
{4.11—5.57,
29.8—40.3} {3.5—4.6 , 34—46 4
26—33} {3.5—4.6 ,
26—33}
11
R 34—46
{3.5—4.6 ,
5 R 26—33}
7

SST 1
40.3—54.7
{4.11—5.57,
29.8—40.3} 34—46
{3.5—4.6 ,
26—33} 2
R

38—51
{3.9—5.2 ,
29—37}
R

3
38—51 {3.9—5.2 , 29—37}

43—60 {4.4—6.1, 32—44}

A N·m {kgf·m, ft·lbf}

ac9uuw00000307

1 Main silencer (RH) 6 Rear HO2S (RH)

2 Main silencer (LH) (See 01-40-23 REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
3 Presilencer
7 Rear HO2S (LH)
4 Middle pipe (See 01-40-23 REAR HEATED OXYGEN SENSOR
5 Front pipe (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
8 WU-TWC (RH) bracket (L type)

01-15–2
1890-1U-06H(01-15).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時４７分

EXHAUST SYSTEM [MZI-3.5]

9 WU-TWC (LH) bracket (L type) 13 Front HO2S (LH)
10 WU-TWC (RH) (See 01-40-20 FRONT HEATED OXYGEN
(See 01-15-3 Warm Up Three Way Catalytic SENSOR (HO2S) REMOVAL/INSTALLATION [MZI-
Converter (WU-TWC) (RH) Removal Note.) 3.5].)
(See 01-15-3 Warm Up Three Way Catalytic 14 Exhaust manifold insulator (RH)
Converter (WU-TWC) (RH) Installation Note.) 15 Exhaust manifold insulator (LH)
11 WU-TWC (LH) (See 01-15-3 Exhaust Manifold Insulator (LH)
(See 01-15-3 Warm Up Three Way Catalytic Removal Note.) 01-15
Converter (WU-TWC) (LH) Installation Note.) 16 Exhaust manifold (RH)
12 Front HO2S (RH) 17 Exhaust manifold (LH)
(See 01-40-20 FRONT HEATED OXYGEN
SENSOR (HO2S) REMOVAL/INSTALLATION [MZI-
3.5].)

Warm Up Three Way Catalytic Converter (WU-TWC) (RH) Removal Note

2WD
1. Remove the joint shaft. (See 03-13-4 JOINT SHAFT REMOVAL/INSTALLATION [2WD].)
2. Remove the WU-TWC (RH).

AWD
1. Remove the joint shaft. (See 03-13-5 JOINT SHAFT REMOVAL/INSTALLATION [AWD].)
2. Remove the insulator. (See 06-14-9 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)
3. Remove the No.1 engine mount (transaxle side). (See 01-10-41 ENGINE REMOVAL/INSTALLATION [MZI-
3.5].)
4. Push up the engine.
5. Remove the WU-TWC (RH).

Exhaust Manifold Insulator (LH) Removal Note

1. Set the fan control module out of the way. (See 01-12-14 FAN MOTOR REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the exhaust manifold Insulator (LH).

Warm Up Three Way Catalytic Converter (WU-TWC) (LH) Installation Note

1. Install the WU-TWC (LH) insulator.
2. Temporarily tighten WU-TWC (LH) bracket.
3. Temporarily tighten WU-TWC (LH) bracket (L type) (engine side).
4. Install the WU-TWC (LH).
5. Install the WU-TWC (LH) bracket.
6. Install the WU-TWC (LH) bracket (L type).

Warm Up Three Way Catalytic Converter (WU-TWC) (RH) Installation Note

2WD
1. Install the WU-TWC (RH) insulator.
2. Temporarily tighten WU-TWC (RH) bracket.
3. Temporarily tighten WU-TWC (RH) bracket (L type) (engine side).
4. Install the WU-TWC (RH).
5. Install the WU-TWC (RH) bracket.
6. Install the WU-TWC (RH) bracket (L type).

AWD
1. Install the WU-TWC (RH) insulator.
2. Temporarily tighten WU-TWC (RH) bracket.
3. Temporarily tighten WU-TWC (RH) bracket (L type) (engine side).
4. Push up the engine.
5. Install the WU-TWC (RH).
6. Install the No.1 engine mount (transaxle side). (See 01-10-41 ENGINE REMOVAL/INSTALLATION [MZI-3.5].)
7. Install the insulator. (See 06-14-9 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)
8. Install the joint shaft. (See 03-13-5 JOINT SHAFT REMOVAL/INSTALLATION [AWD].)
9. Install the WU-TWC (RH) bracket.
End Of Sie

01-15–3
1890-1U-06H(01-16).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

01-16 EMISSION SYSTEM [MZI-3.5]
EMISSION SYSTEM LOCATION Resistance Inspection . . . . . . . . . . . . . . 01-16–11
INDEX [MZI-3.5] . . . . . . . . . . . . . . . . . . 01-16–2 Circuit Open/Short Inspection . . . . . . . . 01-16–11
Engine Compartment Side. . . . . . . . . . 01-16–2 POSITIVE CRANKCASE
Exhaust System Side. . . . . . . . . . . . . . 01-16–3 VENTILATION (PCV) VALVE HEATER
Fuel Tank Side . . . . . . . . . . . . . . . . . . . 01-16–3 FITTING REMOVAL/INSTALLATION
EMISSION SYSTEM DIAGRAM [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-16–12 01-16
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-16–5 POSITIVE CRANKCASE VENTILATION
CHARCOAL CANISTER, (PCV) VALVE HEATER FITTING
CANISTER VENT (CV) SOLENOID INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-16–13
VALVE, AIR FILTER COMPONENT Resistance Inspection . . . . . . . . . . . . . . 01-16–13
REMOVAL/INSTALLATION Circuit Open/Short Inspection . . . . . . . . 01-16–13
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-16–5 ROLLOVER VALVE
CHARCOAL CANISTER, CANISTER VENT REMOVAL/INSTALLATION
(CV) SOLENOID VALVE, AIR FILTER [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-16–14
COMPONENT INSPECTION ROLLOVER VALVE INSPECTION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-16–6 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-16–14
Airflow Inspection . . . . . . . . . . . . . . . . . 01-16–6 FUEL SHUT-OFF VALVE
CV Solenoid Valve Circuit REMOVAL/INSTALLATION
Open/Short Inspection . . . . . . . . . . . . 01-16–6 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-16–14
FUEL-FILLER CAP INSPECTION FUEL SHUT-OFF VALVE INSPECTION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-16–7 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-16–14
Leakage Inspection . . . . . . . . . . . . . . . 01-16–7 QUICK RELEASE CONNECTOR
PURGE SOLENOID VALVE (EMISSION SYSTEM)
REMOVAL/INSTALLATION REMOVAL/INSTALLATION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-16–8 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-16–15
PURGE SOLENOID VALVE Quick Release Connector Type. . . . . . . 01-16–15
INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-16–8 Type A Removal . . . . . . . . . . . . . . . . . . 01-16–15
Airflow Inspection . . . . . . . . . . . . . . . . . 01-16–8 Type B Removal . . . . . . . . . . . . . . . . . . 01-16–16
Circuit Open/Short Inspection . . . . . . . 01-16–9 Type C Removal . . . . . . . . . . . . . . . . . . 01-16–16
POSITIVE CRANKCASE VENTILATION Type D Removal . . . . . . . . . . . . . . . . . . 01-16–16
(PCV) VALVE Type E Removal . . . . . . . . . . . . . . . . . . 01-16–17
REMOVAL/INSTALLATION Type A Installation . . . . . . . . . . . . . . . . . 01-16–17
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-16–10 Type B Installation . . . . . . . . . . . . . . . . . 01-16–18
POSITIVE CRANKCASE Type C Installation. . . . . . . . . . . . . . . . . 01-16–18
VENTILATION (PCV) VALVE Type D Installation. . . . . . . . . . . . . . . . . 01-16–19
INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-16–10 Type E Installation . . . . . . . . . . . . . . . . . 01-16–19
Airflow Inspection . . . . . . . . . . . . . . . . . 01-16–10

End of Toc
WM: EMISSION SYSTEM

01-16–1
1890-1U-06H(01-16).fm 2 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

EMISSION SYSTEM LOCATION INDEX [MZI-3.5]
id0116d1803700
Engine Compartment Side

3
2

ac9uuw00000136
.

1 Purge solenoid valve 3 PCV valve heater fitting

(See 01-16-8 PURGE SOLENOID VALVE (See 01-16-12 POSITIVE CRANKCASE
REMOVAL/INSTALLATION [MZI-3.5].) VENTILATION (PCV) VALVE HEATER FITTING
(See 01-16-8 PURGE SOLENOID VALVE REMOVAL/INSTALLATION [MZI-3.5].)
INSPECTION [MZI-3.5].) (See 01-16-13 POSITIVE CRANKCASE
2 PCV valve VENTILATION (PCV) VALVE HEATER FITTING
(See 01-16-10 POSITIVE CRANKCASE INSPECTION [MZI-3.5].)
VENTILATION (PCV) VALVE REMOVAL/ 4 Quick release connector
INSTALLATION [MZI-3.5].) (See 01-16-15 QUICK RELEASE CONNECTOR
(See 01-16-10 POSITIVE CRANKCASE (EMISSION SYSTEM) REMOVAL/INSTALLATION
VENTILATION (PCV) VALVE INSPECTION [MZI- [MZI-3.5].)
3.5].)

01-16–2
1890-1U-06H(01-16).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

Exhaust System Side
1 WU-TWC (RH)
2 WU-TWC (LH)

01-16

ac9uuw00000179

Fuel Tank Side

2WD
2

4 3

5 1

ac9uuw00000267

01-16–3
1890-1U-06H(01-16).fm 4 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

AWD
2

4 3

5 1

ac9uuw00000268

1 Charcoal canister, CV solenoid valve, air filter 3 Rollover valve

component (See 01-16-14 ROLLOVER VALVE REMOVAL/
(See 01-16-5 CHARCOAL CANISTER, CANISTER INSTALLATION [MZI-3.5].)
VENT (CV) SOLENOID VALVE, AIR FILTER (See 01-16-14 ROLLOVER VALVE INSPECTION
COMPONENT REMOVAL/INSTALLATION [MZI- [MZI-3.5].)
3.5].) 4 Fuel shut-off valve
(See 01-16-6 CHARCOAL CANISTER, CANISTER (See 01-16-14 FUEL SHUT-OFF VALVE REMOVAL/
VENT (CV) SOLENOID VALVE, AIR FILTER INSTALLATION [MZI-3.5].)
COMPONENT INSPECTION [MZI-3.5].) (See 01-16-14 FUEL SHUT-OFF VALVE
2 Fuel-filler cap INSPECTION [MZI-3.5].)
(See 01-16-7 FUEL-FILLER CAP INSPECTION 5 Quick release connector
[MZI-3.5].) (See 01-16-15 QUICK RELEASE CONNECTOR
(EMISSION SYSTEM) REMOVAL/INSTALLATION
[MZI-3.5].)

End Of Sie

01-16–4
1890-1U-06H(01-16).fm 5 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

EMISSION SYSTEM DIAGRAM [MZI-3.5]
id0116d1803600

VENTILATION HOSE
PURGE SOLENOID
VALVE
CHARCOAL
FUEL SHOT-OFF CANISTER
VALVE 01-16
CV SOLENOID
VALVE PCV VALVE
FUEL- HEATER FITTING
FILLER
CAP

AIR FILTER

PCV VALVE : TO PCM

2WD AWD

ROLLOVER ROLLOVER
VALVE VALVE
WU-TWC (RH)

WU-TWC (LH)
ac9uuw00000183

End Of Sie
CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID VALVE, AIR FILTER COMPONENT REMOVAL/
WM: EVAP CONTROL SYSTEM COMPONENT

INSTALLATION [MZI-3.5]
id0116d1819100
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)

Note
• Remove the charcoal canister, CV solenoid valve, and air filter as a single unit.

2. Remove in the order indicated in the table.

3. Install in the reverse order of removal.

6
2

5
3
4

7.8—10.8 1
{80—110,
70—95}

7.8—10.8
{80—110,
70—95}
7.8—10.8
{80—110,
70—95} N·m {kgf·m, ft·lbf}
ac9uuw00000312

1 Under guard (LH) Quick release connector

2 CV solenoid valve connector (See 01-16-15 QUICK RELEASE CONNECTOR
4
(EMISSION SYSTEM) REMOVAL/INSTALLATION
Quick release connector [MZI-3.5].)
(See 01-16-15 QUICK RELEASE CONNECTOR
3 5 Evaporative hose
(EMISSION SYSTEM) REMOVAL/INSTALLATION
[MZI-3.5].) Charcoal canister, CV solenoid valve, air filter
6
component

01-16–5
1890-1U-06H(01-16).fm 6 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

End Of Sie

CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID VALVE, AIR FILTER COMPONENT INSPECTION
[MZI-3.5]
id0116d1819900
Airflow Inspection
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the charcoal canister, CV solenoid valve, air filter component. (See 01-16-5 CHARCOAL CANISTER,
CANISTER VENT (CV) SOLENOID VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.5].)
3. Plug the purge solenoid valve side of the charcoal
canister.
4. Pressurizing from the fuel tank side of the
charcoal canister, verify that there is no leak from TO ATMOSPHERE
the charcoal canister and that the CV solenoid
valve is closed.
• If malfunction, replace the charcoal canister,
CV solenoid valve, air filter component. (See TO PURGE
01-16-5 CHARCOAL CANISTER, CANISTER SOLENOID VALVE
VENT (CV) SOLENOID VALVE, AIR FILTER
COMPONENT REMOVAL/INSTALLATION FROM FUEL TANK
[MZI-3.5].)
ac9uuw00000336

5. Connect the battery positive voltage to CV

solenoid valve terminal A. CV SOLENOID VALVE
6. Pressurizing from the fuel tank side of the WIRING HARNESS-SIDE CONNECTOR
charcoal canister, verify that the CV solenoid
valve is open and that there is airflow through the
air filter. B A
• If malfunction, replace the charcoal canister,
CV solenoid valve, air filter component. (See
01-16-5 CHARCOAL CANISTER, CANISTER
VENT (CV) SOLENOID VALVE, AIR FILTER
COMPONENT REMOVAL/INSTALLATION
[MZI-3.5].)
ac9uuw00000588
7. Pressurizing from the air filter side, verify that the
CV solenoid valve is open and that there is airflow
through the air filter.
• If malfunction, replace the charcoal canister, CV solenoid valve, air filter component. (See 01-16-5
CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID VALVE, AIR FILTER COMPONENT
REMOVAL/INSTALLATION [MZI-3.5].)

CV Solenoid Valve Circuit Open/Short Inspection

1. Disconnect the PCM connector.
2. Inspect the following wiring harness for open or
short circuit (continuity check). CV SOLENOID VALVE
WIRING HARNESS-SIDE CONNECTOR

B A

ac9uuw00000588

01-16–6
1890-1U-06H(01-16).fm 7 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

01-16
1BR 1BM 1BH 1BD 1AZ 1AV 1AR AN1 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

ac9uuw00001007

Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— CV solenoid valve terminal B and PCM terminal 1Z
— CV solenoid valve terminal A and battery
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness
— CV solenoid valve terminal B and power supply
— CV solenoid valve terminal B and body ground
End Of Sie
FUEL-FILLER CAP INSPECTION [MZI-3.5]
WM: FUEL FILLER CAP

id0116d1801300
Leakage Inspection
1. Perform the following SST (Evaporative Emission System Tester 134-01049) self-test:

Note
• If the tester does not work correctly during self-test, refer to the tester operators manual for more detailed
procedures.

(1) Verify that the gas cylinder valve is closed and the control valve located on the tester is in the TEST
position. All tester displays should be off at this time.
(2) Connect the long hose (part of SST) to the
tester.
(3) Connect the manifold assembly (part of SST)
to the long hose as shown.
(4) Open the gas cylinder valve and verify the gas
cylinder regulator left gauge reads 69—82
MANIFOLD ASSEMBLY
kPa {0.71—0.83 kgf/cm2, 10—12 psi}
(preset at factory).
• If not, refer to the tester operators manual LONG HOSE
to contact tester manufacturer.
(5) Press the ON/OFF switch to turn on the SST TO TESTER
and make sure the left display reads 0.0. ac9uuw00000195
(6) Turn the control valve on the tester to the FILL
position.
(7) Verify the left display reading is within 13.9 to 14.0 in of water.
• If not, adjust the pressure using the regulator knob located on the right side of the tester.
(8) Turn the control valve to TEST position and press the START switch.
(9) After the 2-min countdown (left display) is completed, the right display shows the total pressure loss for that
period. A 0.5 in of water loss is acceptable on the self-test.
• If the loss is more than 0.5 in of water, do one or more self-test. If the failed test repeats, check for leak
using the ultrasonic leak detector (part of SST).
2. Press the RESET switch to set the left display reading to 0.0.
3. Connect the fuel cap receiver assembly (part of SST) to the manifold assembly and fuel-filler cap from the
vehicle.
• If the fuel-filler cap is not a genuine part, replace it.

01-16–7
1890-1U-06H(01-16).fm 8 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

4. Turn the control valve to the FILL position.
5. Wait (maximum 20 s) until the left display reads
13.9 to 14.0 in of water.
• If the reading is slightly below the
specification, adjust it using the regulator
knob.
• If the reading is far below, the fuel-filler cap
has leak. Replace it.
6. Turn the control valve to the TEST position and
press the START switch.
7. After the 2-min countdown (left display) is FUEL CAP RECEIVER
ASSEMBLY
completed, check the test result (the failed/
ac9uuw00000196
passed light on the tester).
• If the green light turns on, the fuel-filler cap is
normal.
• If the red light turns on, the fuel-filler cap has leakage. Replace it.
8. Close the gas cylinder valve.
9. Turn the control valve to the FILL position.
10. Press the ON/OFF switch to turn off the tester.
End Of Sie
PURGE SOLENOID VALVE REMOVAL/INSTALLATION [MZI-3.5]
WM: PURGE SOLENOID VALVE

id0116d1803500
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove in the order indicated in the table. .

1 Purge solenoid valve connector 3

Quick release connector
(See 01-16-15 QUICK RELEASE CONNECTOR
2
(EMISSION SYSTEM) REMOVAL/INSTALLATION 1
[MZI-3.5].)
3 Purge solenoid valve
7.8—10.8
7.8—10.8 {80—110,
3. Install in the reverse order of removal. {80—110, 70—95}
End Of Sie 70—95}
2
N·m {kgf·m, ft·lbf}
ac9uuw00000315

PURGE SOLENOID VALVE INSPECTION [MZI-3.5]

id0116d1800900
Airflow Inspection
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Disconnect the quick release connector from the purge solenoid valve. (See 01-16-15 QUICK RELEASE
CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the purge solenoid valve. (See 01-16-8 PURGE SOLENOID VALVE REMOVAL/INSTALLATION [MZI-
3.5].)
4. Verify that the airflow is as indicated in the table.
• If as specified in the table, perform the “Circuit B A
Open/Short Inspection”.
• If not as specified in the table, inspect the
purge solenoid valve. B A
Measured condition Continuity between
A—B
When voltage is not applied No airflow
between terminals A and B
When voltage is applied between Airflow detected
terminals A and B
ac9uuw00000317

01-16–8
1890-1U-06H(01-16).fm 9 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

Circuit Open/Short Inspection
1. Disconnect the PCM connector.
2. Inspect the following wiring harness for an open
or short circuit (continuity check). PURGE SOLENOID VALVE
WIRING HARNESS-SIDE CONNECTOR

B A 01-16

ac9uuw00001008

FUSE BOX
(MAIN RELAY NO.1)

A E

ac9uuw00001020

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR AN1 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

ac9uuw00001009

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
— Purge solenoid valve terminal A and main relay No.1 terminal D
— Purge solenoid valve terminal B and PCM terminal 1BC
Short circuit
• If there is continuity, the circuit is short. Repair or replace the harness.
— Purge solenoid valve terminal A and power supply
— Purge solenoid valve terminal A and body ground
— Purge solenoid valve terminal B and power supply
— Purge solenoid valve terminal B and body ground
End Of Sie
WM: PCV VALVE

01-16–9
1890-1U-06H(01-16).fm 10 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZI-3.5]
id0116d1819800

Caution
• A new PCV valve must be installed if removed from the cylinder head cover.
• Upon removal, damage will occur to the locking mechanism on the PCV valve.

1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove in the order indicated in the table..

1 PCV valve hose

2 PCV valve heater control connector
3 PCV valve
4 O-ring

3. Install in the reverse order of removal.

End Of Sie

3 R

4
OIL

2
ac9uuw00000270

POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZI-3.5]

id0116d1800400

Note
• The PCV valve cannot be reassembled once it is removed because the tabs will have been broken.
Inspect the PCV valve without removing it from the vehicle.

Airflow Inspection
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Disconnect the PCV valve hose from the PCV valve. (See 01-16-10 POSITIVE CRANKCASE VENTILATION
(PCV) VALVE REMOVAL/INSTALLATION [MZI-3.5].)
3. Verify that there is no airflow when pressure is applied to the PCV valve using a vacuum pump.
• If there is airflow, replace the PCV valve. (See 01-16-10 POSITIVE CRANKCASE VENTILATION (PCV)
VALVE REMOVAL/INSTALLATION [MZI-3.5].)
4. Verify that there is airflow when vacuum is applied to the PCV valve.
• If there is no airflow, replace the PCV valve. (See 01-16-10 POSITIVE CRANKCASE VENTILATION (PCV)
VALVE REMOVAL/INSTALLATION [MZI-3.5].)

01-16–10
1890-1U-06H(01-16).fm 11 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

Resistance Inspection
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
3. Disconnect the PCV valve heater control connector.
4. Measure the resistance between the PCV valve
heater control terminals.
• If within the specification, perform out the
“Circuit Open/Short Inspection”. 01-16
• If not within the specification, replace the PCV
valve. (See 01-16-10 POSITIVE B A
CRANKCASE VENTILATION (PCV) VALVE
REMOVAL/INSTALLATION [MZI-3.5].)

PCV valve heater control resistance

10—35 ohm
ac9uuw00000584

Circuit Open/Short Inspection

1. Disconnect the PCM connector.
2. Inspect the following wiring harnesses for open or PCV VALVE HEATER CONTROL
short circuit (continuity check). WIRING HARNESS-SIDE CONNECTOR

B A

ac9uuw00001010

FUSE BOX
(MAIN RELAY NO.1)

A E

ac9uuw00001020

01-16–11
1890-1U-06H(01-16).fm 12 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00000585

Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— PCV valve heater control terminal A and main relay No.1 terminal D
— PCV valve heater control terminal B and PCM terminal 2BL
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— PCV valve heater control terminal A and power supply
— PCV valve heater control terminal A and body ground
— PCV valve heater control terminal B and power supply
— PCV valve heater control terminal B and body ground
End Of Sie
POSITIVE CRANKCASE VENTILATION (PCV) VALVE HEATER FITTING REMOVAL/INSTALLATION [MZI-3.5]
id0116d1105700
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove in the order indicated in the table. .

Approx. 6 N·m
1 PCV valve hose 4 OIL
{61 kgf·cm, 53 in·lbf}
2 PCV valve heater fitting connector 3
3 PCV valve heater fitting
4 O-ring

3. Install in the reverse order of removal.

End Of Sie

ac9uuw00000573

01-16–12
1890-1U-06H(01-16).fm 13 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

POSITIVE CRANKCASE VENTILATION (PCV) VALVE HEATER FITTING INSPECTION [MZI-3.5]
id0116d1105600
Resistance Inspection
1. Disconnect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Disconnect the PCV valve heater fitting connector.
3. Measure the resistance between the PCV valve
terminals.
• If within the specification, perform out the
“Circuit Open/Short Inspection”. 01-16
• If not within the specification, replace the PCV
B A
valve heater fitting. (See 01-16-12 POSITIVE
CRANKCASE VENTILATION (PCV) VALVE
HEATER FITTING REMOVAL/INSTALLATION
[MZI-3.5].)

PCV valve heater fitting resistance

10—35 ohms
ac9uuw00001011

Circuit Open/Short Inspection

1. Disconnect the PCM connector.
2. Inspect the following wiring harnesses for open or PCV VALVE HEATER FITTING
short circuit (continuity check). WIRING HARNESS-SIDE CONNECTOR

B A

ac9uuw00000586

FUSE BOX
(MAIN RELAY NO.1)

A E

ac9uuw00001020

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00000587

01-16–13
1890-1U-06H(01-16).fm 14 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— PCV valve heater fitting terminal A and main relay No.1 terminal D
— PCV valve heater fitting terminal B and PCM terminal 2AU

Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— PCV valve heater fitting terminal A and power supply
— PCV valve heater fitting terminal A and body ground
— PCV valve heater fitting terminal B and power supply
— PCV valve heater fitting terminal B and body ground
End Of Sie
ROLLOVER VALVE REMOVAL/INSTALLATION [MZI-3.5]
WM: ROLLOVER VALVE

id0116d1804600

Note
• The rollover valve cannot be removed as it is built into the fuel tank.

End Of Sie
ROLLOVER VALVE INSPECTION [MZI-3.5]
id0116d1804500

Note
• The rollover valve cannot be disassembled and inspected as it is built into the fuel tank.

1. Perform the fuel tank inspection. (See 01-14-14 FUEL TANK INSPECTION [MZI-3.5].)
End Of Sie
FUEL SHUT-OFF VALVE REMOVAL/INSTALLATION [MZI-3.5]
WM: FUEL SHUT-OFF VALVE

id0116d1809600

Note
• The fuel shut-off valve cannot be removed as it is built into the fuel tank.

End Of Sie
FUEL SHUT-OFF VALVE INSPECTION [MZI-3.5]
id0116d1809700

Note
• The fuel shut-off valve cannot be removed and inspected as it is built into the fuel tank.

1. Perform the fuel tank inspection. (See 01-14-14 FUEL TANK INSPECTION [MZI-3.5].)
End Of Sie
WM: QUICK RELEASE CONNECTOR

01-16–14
1890-1U-06H(01-16).fm 15 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.5]
id0116d1805500

Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause
serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this,
always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE
PRECAUTION”.
01-16
Quick Release Connector Type

Caution
• There are five types of quick release connectors. Verify the type and location, and install/remove
properly.

FUEL TANK SIDE ENGINE VENTILATION HOSE

COMPARTMENT SIDE
A
PURGE
SOLENOID VALVE
C
D
C
E B

CHARCOAL CANISTER

2WD AWD

ac9uuw00001155

Type A Removal
1. Release the retainer shown in the figure.
2. Disconnect the quick release connector. QUICK RELEASE
3. Cover the disconnected quick release connector CONNECTOR
and fuel pipe with vinyl sheeting or a similar
material to prevent it from scratches or dirt. RETAINER

ac9uuw00000308

01-16–15
1890-1U-06H(01-16).fm 16 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

Type B Removal

Note
• If the quick release connector is removed, replace the retainer with a new one.

1. Push the retainer.

QUICK RELEASE CONNECTOR
Note
• The quick release connector can be JOINT PORT
removed by pushing the center of the
retainer tabs.
• The retainer is attached to the pipe even
after the connector is disconnected.

2. Pull the connector side and disconnect the quick RETAINER

release connector.
3. Cover the disconnected quick release connector
ac9uuw00001826
and fuel pipe with vinyl sheeting or a similar
material to prevent it from scratches or dirt.

Type C Removal
1. Move the retainer upward using a small flathead
screwdriver or a similar tool. FLATHEAD
SCREWDRIVER RETAINER
2. Pull out the fuel hose straight from the fuel pipe
and disconnect it.
3. Cover the disconnected quick release connector
and fuel pipe with vinyl sheeting or a similar
material to prevent it from scratches or dirt.

QUICK RELEASE
CONNECTOR
acxuuw00000059

Type D Removal

Caution
• The quick release connector may be damaged if the release tab is bent excessively. Do not expand
the release tab over the stopper.

Note
• The fuel hose can be removed by pushing it to the pipe side to release the lock.

1. Rotate the release tab on the quick release

connector to the stopper position.

RELEASE TAB
STOPPER

acxuuw00000054

01-16–16
1890-1U-06H(01-16).fm 17 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

2. Pull out the fuel hose straight from the fuel pipe
and disconnect it.
3. Cover the disconnected quick release connector
and fuel pipe with vinyl sheeting or a similar
material to prevent it from scratches or dirt.

FUEL PIPE FUEL HOSE

01-16

acxuuw00000055

Type E Removal

Caution
• The quick release connector may be damaged if the release tab is bent excessively. Do not expand
the release tab over the stopper.

Note
• The fuel hose can be removed by pushing it to the pipe side to release the lock.

1. Release the retainer shown in the figure.

2. Disconnect the quick release connector.
3. Cover the disconnected quick release connector
and fuel pipe with vinyl sheeting or a similar
material to prevent it from scratches or dirt.

RETAINER

ac9uuw00000309

Type A Installation
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
• If there is any malfunction, replace it with a new one.
2. Connect the quick release connector.

QUICK RELEASE
CONNECTOR

RETAINER

ac9uuw00000310

01-16–17
1890-1U-06H(01-16).fm 18 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

Type B Installation

Caution
• Be sure to replace the retainer with a new one to prevent gas leakage.
• To prevent evaporative gas leakage, be sure not to damage the connecting part between the
charcoal canister and pipe, and the locks between the quick release connector and retainer. If any
of them are damaged, replace the charcoal canister or hose with a new one.

Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.
• A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses.
Remove the checker tab from the quick release connector after the connector is completely engaged with
the fuel pipe.

1. Remove the retainer remaining on the charcoal

canister pipe. CHECKER TAB
2. Install a new retainer to the quick release
connector.
3. Reconnect the hose straight to the pipe until a
click is heard.
4. Lightly pull and push the quick release connector
a few times by hand, and then verify that it is
connected securely. NEW FUEL HOSE

am3zzw0000037

Type C Installation

Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
• If there is any malfunction, replace it with a new one.
2. Install the quick release connector.
• Insert the fuel pipe straight to the end of the
quick release connector. 2
• Push down the retainer using a finger.
— If the retainer cannot be pushed down,
push the fuel pipe further to the quick
release connector.
1
3. Lightly pull and push the quick release connector
a few times by hand, and then verify that it is
connected securely.

acxuuw00000061

01-16–18
1890-1U-06H(01-16).fm 19 ページ ２００６年１２月１９日　火曜日　午前１０時４９分

EMISSION SYSTEM [MZI-3.5]

Type D Installation

Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.
• A checker tab is integrated with the quick
release connector for new fuel hoses and
evaporative hoses. Remove the checker tab CHECKER TAB
from the quick release connector after the 01-16
connector is completely engaged with the
fuel pipe.

1. Inspect the fuel hose and fuel pipe sealing

surface for damage and deformation.
• If there is any malfunction, replace it with a NEW FUEL HOSE
new one.
2. Apply a small amount of clean engine oil to the
acxuuw00000060
sealing surface of the fuel pipe.
3. Reconnect the fuel hose straight to the fuel pipe
until a click is heard.

Note
• If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or
has not slipped, and then reconnect the quick release connector.

4. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move2.0—3.0
mm {0.08—0.12 in} and is connected securely.

Type E Installation
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
• If there is any malfunction, replace it with a new one.
2. Install the quick release connector.
• Insert the fuel pipe straight to the end of the
quick release connector. 2
• Push down the retainer using a finger.
— If the retainer cannot be pushed down,
push the fuel pipe further to the quick
1
release connector.
3. Lightly pull and push the quick release connector
a few times by hand, and then verify that it is
connected securely.
End Of Sie
ac9uuw00000311

01-16–19
1890-1U-06H(01-17).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

01-17 CHARGING SYSTEM [MZI-3.5]
CHARGING SYSTEM Generator Lower Bolt
LOCATION INDEX [MZI-3.5]. . . . . . . . . 01-17–1 Removal Note . . . . . . . . . . . . . . . . . . . 01-17–5
BATTERY REMOVAL/INSTALLATION Generator Removal Note . . . . . . . . . . . 01-17–5
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-17–2 Generator Installation Note . . . . . . . . . . 01-17–5
Battery Box Installation Note . . . . . . . . 01-17–2 GENERATOR INSPECTION
BATTERY INSPECTION [MZI-3.5] . . . . . 01-17–2 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-17–5 01-17
Electrolyte Specific Gravity . . . . . . . . . 01-17–2 Generator Warning Light . . . . . . . . . . . . 01-17–5
Battery Voltage. . . . . . . . . . . . . . . . . . . 01-17–3 Generator . . . . . . . . . . . . . . . . . . . . . . . 01-17–6
Back-up Current . . . . . . . . . . . . . . . . . . 01-17–3 Generator Inner Parts . . . . . . . . . . . . . . 01-17–7
BATTERY RECHARGING GENERATOR
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-17–4 DISASSEMBLY/ASSEMBLY
GENERATOR [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-17–10
REMOVAL/INSTALLATION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-17–4

End of Toc
CHARGING SYSTEM LOCATION INDEX [MZI-3.5]
WM: CHARGING SYSTEM

id0117d1800100

1
2

ac9uuw00002172

1 Battery 2 Generator
(See 01-17-2 BATTERY REMOVAL/INSTALLATION (See 01-17-4 GENERATOR REMOVAL/
[MZI-3.5].) INSTALLATION [MZI-3.5].)
(See 01-17-2 BATTERY INSPECTION [MZI-3.5].) (See 01-17-5 GENERATOR INSPECTION [MZI-
(See 01-17-4 BATTERY RECHARGING [MZI-3.5].) 3.5].)
(See 01-17-10 GENERATOR DISASSEMBLY/
ASSEMBLY [MZI-3.5].)

End Of Sie
WM: BATTERY

01-17–1
1890-1U-06H(01-17).fm 2 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

BATTERY REMOVAL/INSTALLATION [MZI-3.5]
id0117d1800500
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
.

1 Negative battery cable 5.0—6.9 {51.0—70.3, 4

44.3—61.0}
3
2 Positive battery cable
3 Battery clamp 1
4 Battery box 2.9—4.9
(See 01-17-2 Battery Box Installation Note.) {29.6—49.9, 5
25.7—43.3}
5 Battery
6 Battery tray 2
8.8—12.7 2.9—4.9
{89.8—129.5, {29.6—49.9,
78.0—112.4} 25.7—43.3}

6
8.8—12.7
{89.8—129.5,
78.0—112.4}

N·m {kgf·cm, in·lbf}

ac9uuw00002174

Battery Box Installation Note

1. Install the battery box so that the side with the
notch points toward the front fender (LH). FRONT FENDER (LH)
End Of Sie

NOTCH

FRONT

ac9uuw00002175

BATTERY INSPECTION [MZI-3.5]

id0117d1800600

Warning
• Since battery acid is toxic, be careful when handling the battery.
• Since battery acid is highly corrosive, be careful not to allow it to contact clothing or the vehicle.
• In case battery acid contacts skin, eyes, or clothing, flush it immediately with running water.
Especially if the acid gets in the eyes, flush with water for more than 15 min and get prompt
medical attention.

Electrolyte Specific Gravity

1. Measure the electrolyte specific gravity using a hydrometer.
• If it is less than the specification, recharge the battery. (See 01-17-4 BATTERY RECHARGING [MZI-3.5].)

Battery electrolyte specific gravity [20 °C {68 °F}]

1.22—1.29

01-17–2
1890-1U-06H(01-17).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

Battery Voltage
1. Inspect the battery as follows:
Step Inspection Action
1 Measure the battery 12.4 V or Go to Step
positive voltage. more 3.
Less Go to the
than next step.
12.4 V 01-17
2 Quick charge for 30 12.4 V or Go to the
min and recheck more next step.
voltage. Less Replace the
than battery.
12.4 V
3 Using the battery load Yes Normal
tester, apply load No Replace the
current (see battery battery.
load test current) and
record battery voltage
after 15 s. Is voltage
more than the
specification?

Battery load test current

80D26L (55): 195 A

Standard specification
Battery temp. (°C {°F}) Minimum voltage (V)
4 {39} 9.3
10 {50} 9.4
16 {61} 9.5
21 {70} 9.6

Back-up Current
1. Verify that the ignition switch is off (key has been removed) and that all doors are closed.
2. Disconnect the negative battery cable.
3. Connect the tester between the negative battery terminal and negative battery cable, leave the battery
undisturbed for 30 min, and then measure the back-up current.
• If not within the specification, measure the back-up current while removing the fuses one by one from the
inside of the main fuse block and the inside of the fuse block.

Note
• If the battery is not left undisturbed for 30 min, the tester will indicate a high value (approx. 300 mA).
• If the key or any electrical accessory is operated within approx. 30 min after the tester is connected, the
battery must be left undisturbed for approx. 30 min from that point.

Caution
• Operating electrical loads while the back-up current is being measured can damage the tester.

Note
• For vehicles with the immobilizer system, the system periodically shifts synchronization of the security
light flashing. Therefore, 60 mA (0.1 s) current is supplied when the security light is illuminated, and 50
mA (2 s) current is supplied when the security light is not illuminated. In addition, the measuring
instrument, which shows the average value, indicates around 55 mA.

Battery back-up current

Vehicles with immobilizer system: 50—60 mA
Vehicles without immobilizer system: 55 mA or less

4. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.
End Of Sie

01-17–3
1890-1U-06H(01-17).fm 4 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

BATTERY RECHARGING [MZI-3.5]
id0117d1800700

Warning
• Keep all flames away from the battery, otherwise evaporated gas from the battery fluid may catch
fire, and cause serious injury.
• Remove the battery filler caps when recharging to prevent battery deformation or damage.

Caution
• Do not quick charge for more than 30 min. It will damage the battery.

1. Remove the battery and then place it in a pan of

water.
2. Remove the battery filler caps.
3. Connect a battery charger to the battery and
BATTERY BATTERY
adjust the charging current as follows.
CHARGER

Battery slow charge current

80D26L (55): 5.5—6.5 A

Battery quick charge current [30 min]

80D26L (55): 35 A
acxuuw00002033
4. After the battery is recharged, verify that the
voltage is within the specification and remains at
the same value for 1 h or more after the recharging has been completed.
• If not within the specification, replace the battery.

Standard voltage
12.4 V or more

End Of Sie
GENERATOR REMOVAL/INSTALLATION [MZI-3.5]
WM: GENERATOR

id0117d1800200

Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or
serious injury.
• When the battery cables are connected, touching the vehicle body with generator terminal B will
generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the following operation.

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
3. Remove the air cleaner and fresh air duct component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
4. Remove the cooling fan component. (See 01-12-14 FAN MOTOR REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove the front splash shield (RH).
6. Remove the generator and A/C drive belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-3.5].)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. Refill the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)

01-17–4
1890-1U-06H(01-17).fm 5 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

10. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5].)
.

1 Terminal B cable
2 Generator connector
3 Generator lower bolt
(See 01-17-5 Generator Lower Bolt Removal Note.)
4 Generator
(See 01-17-5 Generator Removal Note.)
(See 01-17-5 Generator Installation Note.) 9.8—14.7 N·m
01-17
{100—149 kgf·cm,
87—130 in·lbf}

2
A

3
48 {4.9, 35}

48 {4.9, 35}
4
A
N·m {kgf·m, ft·lbf}

ac9uuw00002256

Generator Lower Bolt Removal Note

Note
• The generator lower bolt cannot be fully
removed from the engine because it
contacts the body frame. However, the
generator can be removed/installed without
fully removing the lower bolt because there
is a notch at the lower bolt installation part of
the generator.

1. Fully loosen the generator lower bolt.

NOTCH
ac9uuw00002201

Generator Removal Note

1. Remove the generator from above the engine compartment.

Generator Installation Note

1. Tighten the upper and lower bolts temporarily.
2. Tighten the upper bolt to the specified tightening torque.
3. Tighten the lower bolt to the specified tightening torque.
End Of Sie
GENERATOR INSPECTION [MZI-3.5]
id0117d1800300
Generator Warning Light
1. Verify that the battery is fully charged.
2. Verify that the generator and A/C drive belt deflection/tension is correct. (See 01-10-4 DRIVE BELT
INSPECTION [MZI-3.5].)
3. With the ignition switch turned to the ON position, verify that the generator warning light illuminates.
• If it does not illuminate, inspect the generator warning light and the wiring harness.
— If the generator warning light and the wiring harness are normal, inspect the PCM.
4. Verify that the generator warning light goes out after the engine is started.
• If it does not go out, inspect if any DTCs are displayed.
— If any DTCs are displayed, carry out troubleshooting according to the corresponding DTC inspection.

01-17–5
1890-1U-06H(01-17).fm 6 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

Generator
Voltage
1. Verify that the battery is fully charged.
2. Verify that the generator and A/C drive belt deflection/tension is correct. (See 01-10-4 DRIVE BELT
INSPECTION [MZI-3.5].)
3. Turn off all electrical loads.
4. Start the engine.
5. Verify that the generator rotates smoothly without any noise while the engine is running.
• If there is any noise, find the cause and repair or replace the generator.
6. Measure the voltage at each terminal using a
tester.
• If it is not as specified, find the cause and
repair or replace the applicable part.
A B RC LI
Generator standard voltage [IG-ON]
Terminal B: B+
Terminal A: B+
Terminal RC: Approx. 1 V or less
Terminal LI: Approx. 1 V

Generator standard voltage [Idle, 20 °C {68

°F}]
ac9uuw00002202

Terminal B: 12—16 V
Terminal A: 12—16 V
Terminal RC: 0—16 V
Terminal LI: 1—16 V

Current

Note
• Since the charging current decreases rapidly after starting the engine, carry out the following procedure
quickly, and read the maximum current value.

1. Verify that the battery is fully charged.

2. Verify that the generator and A/C drive belt deflection/tension is correct. (See 01-10-4 DRIVE BELT
INSPECTION [MZI-3.5].)
3. Disconnect the negative battery cable.
4. Connect a tester, which can read 120 A or more, between generator terminal B and the wiring harness.
5. Connect the negative battery cable.
6. Turn off all electrical loads.
7. Start the engine.
8. Increase engine speed to 2,500 rpm.

Note
• When the electrical load on the vehicle is low, the specified current cannot be verified although the
generator is normal. In this case, increase the electrical load (Leave the headlights turned on for a while,
then discharge the battery, or use a similar method.) and recheck.
• When the generator itself or the ambient temperature are too high, the specified current also cannot be
verified. In this case, cool down the generator and recheck.

9. Turn the following electrical loads on and verify that the current reading increases more than the minimum
value indicated below.
• Headlights (high-beam)
• Blower motor (HI)
• Rear window defroster
• Brake lights

Generator generated current minimum value

70 % of the nominal output current (nominal output current: 110 A)
[Ambient temp. 20 °C {68 °F}, voltage 13.0—15.0 V, both engine and generator are hot]

01-17–6
1890-1U-06H(01-17).fm 7 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

Generator Inner Parts
Rotor
1. Measure the resistance between the slip rings
using a tester.
• If not within the specification, replace the
rotor.

Generator rotor resistance (between slip 01-17

rings) [20 °C {68 °F}]
1.8—2.2 ohm

acxuuw00002021

2. Verify that there is no continuity between the slip

ring and core using a tester.
• If there is continuity, replace the rotor.
3. Inspect the slip ring surface condition.
• If the slip ring surface is rough, use a lathe or
fine sandpaper to smooth it.

acxuuw00002022

Stator coil
1. Verify that the continuity is as indicated in the
table.

1 6

2 5
3 4

acxuuw00002023

• If there is any malfunction, replace the stator.

: Continuity
Terminal
1 2 3 4 5 6

acxuuw00002024

01-17–7
1890-1U-06H(01-17).fm 8 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

2. Verify that there is no continuity between the
stator coil leads and core using a tester.
• If there is continuity, replace the stator coil.

acxuuw00002025

Brush
1. Inspect brushes for wear.
• If any brush is worn almost to or beyond the
limit, replace all of the brushes.
MINIMUM
Generator brush length
Standard: 22.5 mm {0.89 in}
Minimum: 5.0 mm {0.20 in}
STANDARD

acxuuw00002026

Brush spring
1. Measure the force of the brush spring using a spring pressure gauge.
2. Read the spring pressure gauge at the brush tip
projection of 2 mm {0.079 in}.
• Replace the brush spring if necessary.

Generator brush spring force

Standard: 4.1—5.3 N {0.42—0.54 kgf, 0.92— 2 mm
{0.079 in}
1.19 lbf}
Minimum: 1.7 N {0.17 kgf, 0.38 lbf}

acxuuw00002027

Rectifier (Using an analog circuit tester)

1. Inspect for continuity of the diodes using an
analog circuit tester. P4 P5
P6
• If not as specified, replace the rectifier.
Specification P3
Negative Positive Continuity
P2
E P1, P2, P3, P4, Yes
B P5, P6 No P1
P1, P2, P3, P4, E No
P5, P6 B Yes
E B

acxuuw00002028

01-17–8
1890-1U-06H(01-17).fm 9 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

Rectifier (Using a digital circuit tester)
1. Inspect for continuity of the diodes using a digital circuit tester.
• If not as specified, replace the rectifier.
Specification
Negative Positive Continuity
E P1, P2, P3, P4, No
B P5, P6 Yes
P1, P2, P3, P4, E Yes 01-17
P5, P6 B No

Bearing
1. Inspect for abnormal noise, looseness, and
sticking.
• Replace the bearing if necessary.
End Of Sie

acxuuw00002029

01-17–9
1890-1U-06H(01-17).fm 10 ページ ２００６年１２月１９日　火曜日　午前１０時５１分

CHARGING SYSTEM [MZI-3.5]

GENERATOR DISASSEMBLY/ASSEMBLY [MZI-3.5]
id0117d1800400

Caution
• Melt the solder quickly, otherwise the diodes (rectifier) and regulator will be damaged by excessive
heat.

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

4 1
6 2
3.4—5.4
{35—55, 31—47}

2.9—4.9
{30—50, 5
26—43}
6.9—10.8
{70—110, 61—96}

98—137 N·m 3 10
{10.0—13.9 kgf·m, 2.9—4.9
72—101 ft·lbf} {30—50,
26—43} 8
2.9—4.9
{30—50, 26—43}

9
1.5—2.5
{15—25, 13—22}

7
1.5—2.5
{15—25, 13—22}

N·m {kgf·cm, in·lbf}

ac9uuw00002173

1 Rotor component 6 Front cover

2 Stator coil component 7 Stator coil
3 Pulley 8 Rectifier
4 Rotor 9 Brush holder
5 Front bearing 10 Rear cover

End Of Sie

01-17–10
1890-1U-06H(01-18).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時５３分

IGNITION SYSTEM [MZI-3.5]

01-18 IGNITION SYSTEM [MZI-3.5]
IGNITION SYSTEM SPARK PLUG
LOCATION INDEX [MZI-3.5]. . . . . . . . . 01-18–1 REMOVAL/INSTALLATION
IGNITION COIL [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-18–3
REMOVAL/INSTALLATION SPARK PLUG INSPECTION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-18–2 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-18–3
IGNITION COIL INSPECTION Specification . . . . . . . . . . . . . . . . . . . . . 01-18–3 01-18
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-18–2 Spark Plug Gap Inspection . . . . . . . . . . 01-18–3
Secondary Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 01-18–3
Resistance Inspection . . . . . . . . . . . . 01-18–2 Visual Inspection . . . . . . . . . . . . . . . . . . 01-18–4
Resistance Inspection . . . . . . . . . . . . . . 01-18–4

End of Toc
IGNITION SYSTEM LOCATION INDEX [MZI-3.5]
WM: IGNITION SYSTEM

id0118c1800100

ac9uuw00002161

1 Ignition coil 2 Spark plug

(See 01-18-2 IGNITION COIL REMOVAL/ (See 01-18-3 SPARK PLUG REMOVAL/
INSTALLATION [MZI-3.5].) INSTALLATION [MZI-3.5].)
(See 01-18-2 IGNITION COIL INSPECTION [MZI- (See 01-18-3 SPARK PLUG INSPECTION [MZI-
3.5].) 3.5].)

End Of Sie
WM: IGNITION COIL

01-18–1
1890-1U-06H(01-18).fm 2 ページ ２００６年１２月１９日　火曜日　午前１０時５３分

IGNITION SYSTEM [MZI-3.5]

IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5]
id0118c1800200
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Remove the dynamic chamber. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove in the order indicated in the table.

Caution
• Apply small amount of the specified dielectric grease to the inside of the ignition coils, then install
the ignition coils to the spark plugs.
— Specified grease: Motorcraft XG-3A

5. Install in the reverse order of removal.. 5.0—7.0

1 Connector {51—71, 45—61}

2 Ignition coil

2 1
End Of Sie

GREASE
N·m {kgf·cm, in·lbf}
ac9uuw00002162

IGNITION COIL INSPECTION [MZI-3.5]

id0118c1800300
Secondary Coil Resistance Inspection
1. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5].)
2. Using a tester, measure the resistance between
the ignition coil terminal A and ignition coil boot A
socket.
• If not within the specification, replace the
ignition coil.

Ignition coil secondary coil resistance

5—6 kilohms

End Of Sie
WM: SPARK PLUG

ac9uuw00002498

01-18–2
1890-1U-06H(01-18).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時５３分

IGNITION SYSTEM [MZI-3.5]

SPARK PLUG REMOVAL/INSTALLATION [MZI-3.5]
id0118c1800400

Caution
• If a spark plug that is not as specified is installed, engine performance will be deteriorated. Install
only the specified spark plug when replacing.

1. Disconnect the negative battery cable.

2. Remove the engine cover. 01-18
3. Remove the dynamic chamber. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove the spark plugs using a plug-wrench.

Caution
• Apply small amount of the specified dielectric grease to the inside of the ignition coils, then install
the ignition coils to the spark plugs.
— Specified grease: Motorcraft XG-3A

6. Install in the reverse order of removal.

Tightening torque
9—20 N·m {91—204 kgf·cm, 79—177 in·lbf}

End Of Sie
SPARK PLUG INSPECTION [MZI-3.5]
id0118c1800500
Specification

Spark plug type

ZZJ1 18 110

Spark Plug Gap Inspection

Caution
• To avoid possible damage to the tip, do not adjust the plug gap.
• To prevent damaging the tip, use a wire type plug gap gauge when inspecting the plug gap.

1. Measure the spark plug gap using a wire type plug gap gauge.
• If not within the specification, replace the spark plug.

Spark plug gap

1.29—1.45 mm {0.051—0.057 in}

Cleaning

Caution
• Carbon may adhere to the tip of the spark plug during vehicle delivery or repeated short distance
driving during the winter time. If there is any malfunction such as rough idling or start difficulty
due to carbon adhesion causing plug fouling, burn off the carbon by performing no-load racing of
the engine.
• When performing the no-load racing, apply the side brake and foot brake, move the selector lever
to P position to prevent an accident and serious injury.
• To avoid possible damage to the spark plug tip, do not use a wire brush for cleaning.

Note
• To avoid possible damage to the tip, use gasoline to clean the spark plugs after removing dirt.
• If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to
the idle speed. This is does not indicate a malfunction.
• Do not perform no-load racing at high engine speed continuously for 10 s or more.

1. If there is carbon adhering to the spark plug, perform no-load racing at 4,000 rpm for 2 min, 2 times.

01-18–3
1890-1U-06H(01-18).fm 4 ページ ２００６年１２月１９日　火曜日　午前１０時５３分

IGNITION SYSTEM [MZI-3.5]

Visual Inspection
1. Inspect the following items:
• If any of the following malfunctions are DAMAGE BREAKAGE
indicated, replace the spark plug. BURNS
— Insulator breakage
— Worn electrode
— Damaged gasket
— Badly burned insulator (sparking side) WEAR AND
CARBON
DEPOSITS

atraaw00000524

Resistance Inspection
1. Measure the resistance of the spark plug using a
tester as shown in the figure.
• If not within the specification, replace the
spark plug.

Spark plug resistance

2—20 kilohms

End Of Sie

atraaw00000525

01-18–4
1890-1U-06H(01-19).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時５４分

STARTING SYSTEM [MZI-3.5]

01-19 STARTING SYSTEM [MZI-3.5]
STARTING SYSTEM No-load Test . . . . . . . . . . . . . . . . . . . . . 01-19–2
LOCATION INDEX [MZI-3.5]. . . . . . . . . 01-19–1 Magnetic Switch
STARTER Operation Inspection . . . . . . . . . . . . . . 01-19–3
REMOVAL/INSTALLATION Pinion Gap Inspection . . . . . . . . . . . . . . 01-19–3
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-19–2 Starter Inner Parts Inspection . . . . . . . . 01-19–4
STARTER INSPECTION STARTER 01-19
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-19–2 DISASSEMBLY/ASSEMBLY
On-vehicle Inspection. . . . . . . . . . . . . . 01-19–2 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-19–7

End of Toc
STARTING SYSTEM LOCATION INDEX [MZI-3.5]
WM: STARTING SYSTEM

id0119c1800100

ac9uuw00002163

1 Starter
(See 01-19-2 STARTER REMOVAL/INSTALLATION
[MZI-3.5].)
(See 01-19-2 STARTER INSPECTION [MZI-3.5].)
(See 01-19-7 STARTER DISASSEMBLY/
ASSEMBLY [MZI-3.5].)

End Of Sie
WM: STARTER

01-19–1
1890-1U-06H(01-19).fm 2 ページ ２００６年１２月１９日　火曜日　午前１０時５４分

STARTING SYSTEM [MZI-3.5]

STARTER REMOVAL/INSTALLATION [MZI-3.5]
id0119c1800200

Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or
serious injury.
• When the battery cables are connected, touching the vehicle body with starter terminal B will
generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the following operation.

1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Position the selector cable out of the way.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal..
27 N·m {2.8 kgf·m, 20 ft·lbf}
1 Wiring harness bracket
2 Terminal B cable
3 Terminal S connector 3
4 Starter
9.8—11.7
{100—119,
End Of Sie 87—103}
4

2
7.8—10.8
{79.6—110.1,
69.1—95.5}

1
N·m {kgf·cm, in·lbf}

ac9uuw00002257

STARTER INSPECTION [MZI-3.5]

id0119c1800300
On-vehicle Inspection
1. Verify that the battery is fully charged.
2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
• If the starter does not operate, inspect the following:
— Remove the starter, and inspect the starter unit.
— Inspect the related wiring harnesses, the ignition switch, and the transaxle range switch.

No-load Test
1. Verify that the battery is fully charged.
2. Connect the starter, battery, and a tester as
shown in the figure.
IG SW TESTER
3. Operate the starter and verify that it rotates
A
smoothly.
• If the starter does not rotate smoothly, inspect B

the starter unit. M TESTER

4. Measure the voltage and current while the starter S TERMINAL V BATTERY
is operating. STARTER
• If not within the specification, replace the
starter.

Starter no-load test voltage

acxuuw00002040
11 V

Starter no-load test current

90 A or less

01-19–2
1890-1U-06H(01-19).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時５４分

STARTING SYSTEM [MZI-3.5]

Magnetic Switch Operation Inspection
Pull-out test

Note
• Depending on the battery charge condition, the starter motor pinion may rotate while in an extended state.
This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does
not indicate an abnormality.
01-19
1. Verify that the starter motor pinion is extended TERMINAL S
while battery positive voltage is connected to
terminal S and the starter body is grounded.
• If the starter motor pinion is not extended,
repair or replace the starter.

acxuuw00002041

Return test
1. Disconnect the motor wire from terminal M.
2. Connect battery positive voltage to terminal M
and ground the starter body. TERMINAL M
3. Pull out the drive pinion with a screwdriver. Verify
that it returns to its original position when
released.
• If it does not return, repair or replace the
starter.

acxuuw00002042

Pinion Gap Inspection

1. Pull out the drive pinion with the battery positive TERMINAL S
voltage connected to terminal S and the starter
body grounded.

Caution
• Applying power for more than 10 s can
damage the starter. Do not apply power
for more than 10 s.

acxuuw00002041

01-19–3
1890-1U-06H(01-19).fm 4 ページ ２００６年１２月１９日　火曜日　午前１０時５４分

STARTING SYSTEM [MZI-3.5]

2. Measure the pinion gap while the drive pinion is
extended.
• If not as specified, adjust with an adjustment
washer (between drive housing front cover
and magnetic switch).

Starter pinion gap

0 mm {0 in}

PINION GAP

acxuuw00002043

Starter Inner Parts Inspection

Armature
1. Verify that there is no continuity between the
commutator and the core at each segment using
a tester.
• If there is continuity, replace the armature.

acxuuw00002044

2. Verify that there is no continuity between the

commutator and the shaft using a tester.
• If there is continuity, replace the armature.

acxuuw00002045

3. Place the armature on V-blocks, and measure the

runout using a dial indicator.

Starter armature runout

0.1 mm {0.004 in} max.

acxuuw00002046

01-19–4
1890-1U-06H(01-19).fm 5 ページ ２００６年１２月１９日　火曜日　午前１０時５４分

STARTING SYSTEM [MZI-3.5]

4. Measure the commutator diameter.
• If not within the minimum specification,
replace the armature.

Starter commutator diameter

Standard: 29.4 mm {1.16 in}
Minimum: 28.8 mm {1.13 in}
01-19

acxuuw00002047

5. Measure the segment groove depth of the

commutator.
• If not within the minimum specification,
undercut the grooves to the standard depth.

Segment groove depth of starter commutator

Standard: 0.5 mm {0.02 in}
Minimum: 0.2 mm {0.008 in}

acxuuw00002048

Magnetic switch
1. Inspect for continuity between terminals S and M
TERMINAL S
using a tester. TERMINAL M
• If there is no continuity, replace the magnetic
switch.

acxuuw00002049

2. Inspect for continuity between terminal S and the TERMINAL S

body using a tester.
• If there is no continuity, replace the magnetic
switch.

acxuuw00002050

01-19–5
1890-1U-06H(01-19).fm 6 ページ ２００６年１２月１９日　火曜日　午前１０時５４分

STARTING SYSTEM [MZI-3.5]

3. Verify that there is no continuity between
TERMINAL M
terminals M and B using a tester.
• If there is continuity, replace the magnetic
switch.
TERMINAL B

acxuuw00002051

Brush and brush holder

1. Verify that there is no continuity between each
insulated brush and plate using a tester.
• If there is continuity, replace the brush holder.

acxuuw00002052

2. Measure the brush length.

• If any brush is worn almost to or beyond the
minimum specification, replace all of the
brushes. MINIMUM
BRUSH
Starter brush length LENGTH
Standard: 12.3 mm {0.48 in}
Minimum: 5.5 mm {0.22 in}

CONTACT FACE WITH COMMUTATOR

acxuuw00002053

3. Measure the brush spring force using a spring

balance.
• If not within the minimum specification,
replace the brush and brush holder
component.

Starter brush spring force

Standard: 15.0—20.4 N {1.53—2.08 kgf,
3.38—4.58 lbf}
Minimum: 2.75 N {0.28 kgf, 0.62 lbf}

End Of Sie acxuuw00002054

01-19–6
1890-1U-06H(01-19).fm 7 ページ ２００６年１２月１９日　火曜日　午前１０時５４分

STARTING SYSTEM [MZI-3.5]

STARTER DISASSEMBLY/ASSEMBLY [MZI-3.5]
id0119c1800400
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

1 8.8—12.7
6 5.0—7.1
{90—129, 79—111} {51—72,
45—62}
13 01-19

4.1—7.6 12
{42—77,
37—66} 10

11 2.4—4.4
{25—44,
22—38}

9
2

7
4

8
5 N·m {kgf·cm, in·lbf}
ac9uuw00002165

1 Magnetic switch 8 Pinion

2 Rear housing 9 Front cover
3 Brush and brush holder 10 Lever
4 Armature 11 Drive pinion
5 Yoke 12 Internal gear
6 Planetary gear 13 Gear shaft
7 Pinion shaft

End Of Sie

01-19–7
1890-1U-06H(01-20).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時５５分

CRUISE CONTROL SYSTEM [MZI-3.5]

01-20 CRUISE CONTROL SYSTEM [MZI-3.5]
CRUISE CONTROL
SWITCH INSPECTION [MZI-3.5] . . . . . 01-20–1

End of Toc
CRUISE CONTROL SWITCH INSPECTION [MZI-3.5]
WM: CRUISE CONTROL SWITCH

id0120c1800100 01-20
1. Disconnect the negative battery cable.
2. Remove the driver-side air bag module. (See08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/
INSTALLATION.)
3. Disconnect the cruise control switch connector.
4. Inspect for resistance and continuity between the
cruise control switch terminals using an CRUISE OFF D
ohmmeter. SWITCH E
• If not as specified, replace the cruise control B
switch. CANCEL SWITCH

: Continuity : Resistance : Diode SET(-) SWITCH A B C D E F G H

Terminal
Switch position SET(+) SWITCH
B C D E
Cruise OFF switch RESUME SWITCH
held at on
CANCEL switch CRUISE ON
R1 SWITCH
held at on
SET(-)
R2
switch held at on
C
SET(+) R3 ac9uuw00000454
switch held at on
RESUME
R4
switch held at on
Cruise ON switch
R5
held at on
Neutral R6

R1: 117.6—122.4 ohms R2: 294.0—306.0 ohms

R3: 588.0—612.0 ohms R4: 1087.8—1132.2 ohms
R5: 2067.8—2152.2 ohms R6: 4223.8—4396.2 ohms
ac9uuw00000455

End Of Sie

01-20–1
1890-1U-06H(01-40).fm 1 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

01-40 CONTROL SYSTEM [MZI-3.5]
CONTROL SYSTEM CAMSHAFT POSITION (CMP) SENSOR
LOCATION INDEX [MZI-3.5]. . . . . . . . . 01-40–2 INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-40–18
CONTROL SYSTEM DIAGRAM Visual Inspection . . . . . . . . . . . . . . . . . . 01-40–18
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-40–3 Resistance Inspection . . . . . . . . . . . . . . 01-40–18
PCM REMOVAL/INSTALLATION Circuit Open/Short Inspection . . . . . . . . 01-40–19
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-40–4 FRONT HEATED OXYGEN SENSOR 01-40
PCM INSPECTION [MZI-3.5] . . . . . . . . . 01-40–5 (HO2S) REMOVAL/INSTALLATION
PCM INSPECTION [MZI-3.5]. . . . . . . . 01-40–5 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-40–20
PCM CONFIGURATION [MZI-3.5] . . . . . 01-40–7 HO2S (LH) Removal/Installation . . . . . . 01-40–20
POWER STEERING PRESSURE HO2S (RH) Removal/Installation. . . . . . 01-40–20
(PSP) SWITCH INSPECTION FRONT HEATED OXYGEN SENSOR
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-40–8 (HO2S) INSPECTION [MZI-3.5] . . . . . . . 01-40–21
Continuity Inspection . . . . . . . . . . . . . . 01-40–8 Front Heated Oxygen Sensor (HO2S)
Circuit Open/Short Inspection . . . . . . . 01-40–8 Voltage Inspection. . . . . . . . . . . . . . . . 01-40–21
MASS AIR FLOW (MAF)/INTAKE AIR HO2S Heater
TEMPERATURE (IAT) SENSOR Resistance Inspection . . . . . . . . . . . . . 01-40–21
REMOVAL/INSTALLATION Circuit Open/Short Inspection . . . . . . . . 01-40–22
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-40–9 REAR HEATED OXYGEN SENSOR
MASS AIR FLOW (MAF) SENSOR (HO2S) REMOVAL/INSTALLATION
INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-40–9 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-40–23
Visual Inspection . . . . . . . . . . . . . . . . . 01-40–9 HO2S (LH) Removal/Installation . . . . . . 01-40–23
Voltage Inspection . . . . . . . . . . . . . . . . 01-40–9 HO2S (RH) Removal/Installation. . . . . . 01-40–23
Circuit Open/Short Inspection . . . . . . . 01-40–10 REAR HEATED OXYGEN SENSOR
INTAKE AIR TEMPERATURE (IAT) (HO2S) INSPECTION [MZI-3.5] . . . . . . . 01-40–23
SENSOR INSPECTION [MZI-3.5] . . . . . 01-40–11 Rear Heated Oxygen Sensor (HO2S)
Resistance Inspection . . . . . . . . . . . . . 01-40–11 Voltage Inspection. . . . . . . . . . . . . . . . 01-40–23
Circuit Open/Short Inspection . . . . . . . 01-40–12 HO2S Heater
THROTTLE POSITION (TP) SENSOR Resistance Inspection . . . . . . . . . . . . . 01-40–24
INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-40–12 Circuit Open/Short Inspection . . . . . . . . 01-40–25
Voltage Inspection . . . . . . . . . . . . . . . . 01-40–13 KNOCK SENSOR (KS)
Circuit Open/Short Inspection . . . . . . . 01-40–13 REMOVAL/INSTALLATION
ACCELERATOR PEDAL POSITION [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-40–26
(APP) SENSOR INSPECTION KNOCK SENSOR (KS) INSPECTION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-40–14 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-40–27
Voltage Inspection . . . . . . . . . . . . . . . . 01-40–14 Resistance Inspection . . . . . . . . . . . . . . 01-40–27
Circuit Open/Short Inspection . . . . . . . 01-40–15 Circuit Open/Short Inspection . . . . . . . . 01-40–27
CRANKSHAFT POSITION (CKP) CYLINDER HEAD TEMPERATURE
SENSOR REMOVAL/INSTALLATION (CHT) SENSOR
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-40–16 REMOVAL/INSTALLATION
Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-40–16 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-40–28
CRANKSHAFT POSITION (CKP) CYLINDER HEAD TEMPERATURE
SENSOR INSPECTION (CHT) SENSOR INSPECTION
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-40–17 [MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . . 01-40–28
Visual Inspection . . . . . . . . . . . . . . . . . 01-40–17 Resistance Inspection . . . . . . . . . . . . . . 01-40–28
Resistance Inspection . . . . . . . . . . . . . 01-40–17 Circuit Open/Short Inspection . . . . . . . . 01-40–29
Circuit Open/Short Inspection . . . . . . . 01-40–17 FUEL TANK PRESSURE SENSOR
CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZI-3.5] . . . . . . . . . . . . . 01-40–30
REMOVAL/INSTALLATION Voltage Inspection . . . . . . . . . . . . . . . . . 01-40–30
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-40–18 Circuit Open/Short Inspection . . . . . . . . 01-40–30

End of Toc
WM: ENGINE CONTROL SYSTEM

01-40–1
1890-1U-06H(01-40).fm 2 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

CONTROL SYSTEM LOCATION INDEX [MZI-3.5]
id0140c1804100

8
12

9
11

10
4

7
5
2
ac9uuw00001132

1 PCM 2 MAF/IAT sensor

(See 01-40-4 PCM REMOVAL/INSTALLATION (See 01-40-9 MASS AIR FLOW (MAF)/INTAKE AIR
[MZI-3.5].) TEMPERATURE (IAT) SENSOR REMOVAL/
(See 01-40-5 PCM INSPECTION [MZI-3.5].) INSTALLATION [MZI-3.5].)
(See 01-40-7 PCM CONFIGURATION [MZI-3.5].) (See 01-40-9 MASS AIR FLOW (MAF) SENSOR
INSPECTION [MZI-3.5].)
(See 01-40-11 INTAKE AIR TEMPERATURE (IAT)
SENSOR INSPECTION [MZI-3.5].)

01-40–2
1890-1U-06H(01-40).fm 3 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

3 TP sensor 8 Front HO2S
(See 01-40-12 THROTTLE POSITION (TP) (See 01-40-20 FRONT HEATED OXYGEN
SENSOR INSPECTION [MZI-3.5].) SENSOR (HO2S) REMOVAL/INSTALLATION [MZI-
4 CHT sensor 3.5].)
(See 01-40-28 CYLINDER HEAD TEMPERATURE (See 01-40-21 FRONT HEATED OXYGEN
(CHT) SENSOR REMOVAL/INSTALLATION [MZI- SENSOR (HO2S) INSPECTION [MZI-3.5].)
3.5].) 9 Rear HO2S
(See 01-40-28 CYLINDER HEAD TEMPERATURE (See 01-40-23 REAR HEATED OXYGEN SENSOR
(CHT) SENSOR INSPECTION [MZI-3.5].) (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)
01-40
5 CKP sensor (See 01-40-23 REAR HEATED OXYGEN SENSOR
(See 01-40-16 CRANKSHAFT POSITION (CKP) (HO2S) INSPECTION [MZI-3.5].)
SENSOR REMOVAL/INSTALLATION [MZI-3.5].) 10 PSP switch
(See 01-40-17 CRANKSHAFT POSITION (CKP) (See 01-40-8 POWER STEERING PRESSURE
SENSOR INSPECTION [MZI-3.5].) (PSP) SWITCH INSPECTION [MZI-3.5].)
6 CMP sensor 11 APP sensor
(See 01-40-18 CAMSHAFT POSITION (CMP) (See 01-40-14 ACCELERATOR PEDAL POSITION
SENSOR REMOVAL/INSTALLATION [MZI-3.5].) (APP) SENSOR INSPECTION [MZI-3.5].)
(See 01-40-18 CAMSHAFT POSITION (CMP) 12 Fuel tank pressure sensor
SENSOR INSPECTION [MZI-3.5].) (See 01-40-30 FUEL TANK PRESSURE SENSOR
7 KS INSPECTION [MZI-3.5].)
(See 01-40-26 KNOCK SENSOR (KS) REMOVAL/
INSTALLATION [MZI-3.5].)
(See 01-40-27 KNOCK SENSOR (KS)
INSPECTION [MZI-3.5].)

End Of Sie
CONTROL SYSTEM DIAGRAM [MZI-3.5]
id0140c1800300

THROTTLE VALVE ACTUATOR

CMP SENSOR (RH)
PCV VALVE
PURGE CMP SENSOR (LH)
HEATER MAF/IAT SENSOR
SOLENOID FITTING
FUEL INJECTOR
VALVE
CV SOLENOID OCV
FRONT
VALVE (LH)
HO2S (LH)
OCV AIR CLEANER
FUEL TANK (RH) TP SENSOR
PRESSURE
SENSOR GENERATOR

PCM

PCV VALVE

FRONT IGNITION
HO2S (RH) COIL
2WD AWD
REAR
HO2S (RH) APP SENSOR
KS

REAR
CKP SENSOR
HO2S (LH)
CHT SENSOR : TO PCM
ac9uuw00001361

End Of Sie
WM: PCM

01-40–3
1890-1U-06H(01-40).fm 4 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

PCM REMOVAL/INSTALLATION [MZI-3.5]
id0140c1802400

Note
• For replace the PCM, Setup the M-MDS and perform the PCM configuration. (See 01-40-7 PCM
CONFIGURATION [MZI-3.5].)

1. Disconnect the negative battery cable.

2. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5])

Note
• Only 2 PCM connectors.

3. Disconnect connectors.
4. Remove PCM and bracket as and assembly.
5. Remove PCM from bracket.
6. When replacing the PCM on the vehicles, perform the following.
• PCM parameter reset. (See 09-14-19 IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY
ADDITION AND CLEARING [ADVANCED KEYLESS SYSTEM].) (See 09-14-37 IMMOBILIZER SYSTEM
COMPONENT REPLACEMENT/KEY ADDITION AND CLEARING [KEYLESS ENTRY SYSTEM].)
7. Install in the reverse order of removal.

7.8—10.8
{80—110,
70—95}

7.8—10.8
{80—110, 2
70—85}

1
7.8—10.8
{80—110,
70—95}

7.8—10.8
{80—110,
70—95}
N·m {kgf·cm. in·Ibf}

ac9uuw00002507

1 PCM connector 3 PCM bracket

2 PCM

End Of Sie

01-40–4
1890-1U-06H(01-40).fm 5 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

PCM INSPECTION [MZI-3.5]
id0140c1802500

Caution
• The PCM terminal voltage can vary with the conditions when measuring and changes due to aged
deterioration on the vehicle, causing false diagnosis. Therefore determine comprehensively where
the malfunction occurs among the input systems, output systems, and the PCM.

PCM inspection preparation 01-40

1. Disconnect the negative battery cable.
2. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the windshield wiper arm and blade. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION.)
4. Remove the cowl grille. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
5. Remove the windshield wiper motor. (See 09-19-6 WINDSHIELD WASHER MOTOR REMOVAL/
INSTALLATION.)
6. Remove the cowl panel. (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
7. Remove the PCM connector still connected.
8. Install the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
9. Connect the negative battery cable.

Typical Diagnostic Reference Values

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00002429

Measured/PID Values
Sensors/Inputs Units Measured/PID
KOEO Hot Idle 48 KM/H (30MPH) 89 KM/H (55MPH)
PSP 0.1/LOW VBAT/HIGH (I) 0.1/LOW 0.1/LOW DCV/HIGH-LOW
GENMN (GFS) 11.89/0 VBAT/50 VBAT/28 VBAT/25 DCV/%
APP1 3.9 3.9 3.5 3.3 DCV
APP2 1.6 1.7 1.8 2.1 DCV
APP3 1.0 1.0 1.3 1.5 DCV
FPM OFF ON ON ON ON-OFF
ACP 0.8/70 0.86/73 0.9/75 1.0/87 DCV/psi

01-40–5
1890-1U-06H(01-40).fm 6 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Measured/PID Values
Sensors/Inputs Units Measured/PID
KOEO Hot Idle 48 KM/H (30MPH) 89 KM/H (55MPH)
MAF 0 0.7 1.4 1.5 DCV
MAF SIGRTN 0 0.6-1.9 1-1.6 1.3-2.3 DCV
IAT 80 (K) 50 (K) 37 (K) 34 (K) DEG F
FTP 2.6/-0.01 2.6/-0.01 2.6/-0.01 2.6/-0.01 DCV/psi
BOO VBAT/OFF 0.1/ON (E) VBAT/OFF VBAT/OFF DCV/ON-OFF
BPA 0.1/OFF VBAT/ON (E) 0.1/OFF 0.1/OFF DCV/ON-OFF
FEPS 0.5-0.6 0.5-0.6 0.5-0.6 0.5-0.6 DCV
SCCS 5 0.1(P) 5 5 DCV
HO2S12 (L) (D) (D) (D) DCV
HO2S22 0.1 (D) (D) (D) DCV
HO2S21 0 switching (C) switching (C) switching (C) DCV
HO2S11 (L) switching (C) switching (C) switching (C) DCV
CHT 3.6/199 3.6/199 3.58/201 3.45/208 DCV/DEG F
CMP2 0 5-7 13-16 20-23 Hz
CMP1 0 5-7 13-16 20-23 Hz
CKP 0 400-500 850-1050 1050-1150 Hz
KNOCK 1 23.99k 25.01k 25.73k 44.51k N/A
TP2 1.1/25 0.8/15 1.0/19 1.4/27 DCV/%
TP1 4.1/17 4.4/13 4.2/16 4.0/19 DCV/%
ACCS VBAT/OFF VBAT/ON (A) VBAT/OFF VBAT/OFF DCV/ON-OFF
APP 3.9 0 0 22 %
APP_FLT NO FAULT NO FAULT NO FAULT NO FAULT FAULT- NO FAULT
CPP/PNP NEUTRAL NEUTRAL DRIVE DRIVE NEUTRAL-DRIVE
ETC_ACT 7.56 1.27 6.22 12.74 DEG
ETC_DSD 7.62 1.31 6.19 12.73 DEG
ETC_TRIM 0.23 0.21 0.24 0.24 DEG
FANVAR NO FAULT NO FAULT NO FAULT NO FAULT FAULT- NO FAULT
FLI 71 (H) 72 (H) 82 (H) 81 (H) %
LOAD 51.4 (L) 16.1 35.4 34.7 %
MISFIRE NO NO NO NO YES-NO
RPM 0 600 1200 1500 RPM
VSS 0 0 30 55 MPH
WAC F NO FAULT NO FAULT NO FAULT NO FAULT FAULT- NO FAULT

Actuators/ Measured/PID Values

Outputs KOEO Hot Idle 48 KM/H (30MPH) 89 KM/H (55MPH) Units Measured/PID
GENFDC 3.79 0 0 0 %
SMC 0 0 0 0 DCV
CTO 0 0 0 0 Hz
EVMV 0 337 0 847 mA
EVAPCV 0 0 0 0 %
FP 8.3/75 3.6/27 3.6/27 3.8/29 DCV/%
WAC/ACCR OFF OFF OFF OFF ON-OFF
HTR12 VBAT/OFF 0.2/ON 0.2/ON 0.2/ON DCV/ON-OFF
HTR22 VBAT/OFF 0.2/ON 0.2/ON 0.2/ON DCV/ON-OFF
CD6F (CYL 6) VBAT VBAT VBAT VBAT DCV
CD5D (CYL 5) VBAT VBAT VBAT VBAT DCV
CD4B (CYL 4) VBAT VBAT VBAT VBAT DCV
CD3E (CYL 3) VBAT VBAT VBAT VBAT DCV
CD2C (CYL 2) VBAT VBAT VBAT VBAT DCV
CD1A (CYL 1) VBAT VBAT VBAT VBAT DCV
PCVHC 0 0 0 0 %
TACM (+) 3.7 VBAT VBAT VBAT DCV

01-40–6
1890-1U-06H(01-40).fm 7 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Actuators/ Measured/PID Values
Outputs KOEO Hot Idle 48 KM/H (30MPH) 89 KM/H (55MPH) Units Measured/PID
INJ2 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
INJ4 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
INJ6 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
TACM (-) 3.7 VBAT VBAT VBAT DCV
INJ1 0 2.6-3.2 2.5-5.5 3.5-8.5 mS 01-40
INJ3 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
INJ5 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
VCTADV 0 -.031 -27.56 -30.94 DEG
VCTADV2 0 0 -27.69 -31.06 DEG
HTR11 0.1/ON (O) 0.1/ON 0.1/ON 0.1/ON DCV/ON-OFF
HTR21 0.1/ON (O) 0.1/ON 0.1/ON 0.1/ON DCV/ON-OFF
FANVAR 0 0 0 0 %
FANDC 7.5 7.5 7.5 7.5 %
FP ON/OFF ON ON ON ON-OFF
LONGFT1 (L) (-)20-(+)20 (-)20-(+)20 (-)20-(+)20 %
LONGFT2 (L) (-)20-(+)20 (-)20-(+)20 (-)20-(+)20 %
MIL OFF OFF OFF OFF ON-OFF
SHRTFT1 (L) (-)10-(+)10 (-)10-(+)10 (-)10-(+)10 %
SHRTFT2 (L) (-)10-(+)10 (-)10-(+)10 (-)10-(+)10 %
SPARKADV 10 13.25 44 45.25 DEG
VCTDC 0 0 47.32 80 %
VCTDC2 0 0 46.8 80 %
VCTADVERR 0 0.18 -0.37 -0.18 DEG
VCTADVERR2 0 0.06 -0.43 0 DEG

Measured/PID Values
Other Units Measured/PID
KOEO Hot Idle 48 KM/H (30MPH) 89 KM/H (55MPH)
ETCVREF 5 5 5 5 DCV
VREF 5 5 5 5 DCV
VPWR VBAT VBAT VBAT VBAT DCV
KAPWR VBAT VBAT VBAT VBAT DCV

End Of Sie
PCM CONFIGURATION [MZI-3.5]
id0140c1802600
1. Connect the M-MDS to DLC-2.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select the “Module Programming”.
• When using the PDS (Pocket PC)
1. Select “Programming”.
2. Select “Module Programming”. DLC-2
3. Then, select the “Programmable Module
Installation”, “PCM” from the screen menu.
4. Select “PCM” and perform procedures according
ac9uuw00001090
to directions on the M-MDS screen.
5. Retrieve DTCs by the M-MDS, then verify that
there is no DTC present.
• If a DTC is present, perform the applicable DTC inspection.
End Of Sie
WM: POWER STEERING PRESSURE SWITCH

01-40–7
1890-1U-06H(01-40).fm 8 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

POWER STEERING PRESSURE (PSP) SWITCH INSPECTION [MZI-3.5]
id0140c1803100
Continuity Inspection
1. Disconnect the PSP switch connector.
2. Start the engine.
3. Verify no continuity between the PSP switch terminals while rotating the steering wheel.
• If there is continuity, verify that P/S oil pump is normal and replace the PSP switch. (See 06-14-21 POWER
STEERING OIL PUMP DISASSEMBLY/ASSEMBLY.)
• If the monitor item condition/specification (reference) is not within the specification, even though there is no
malfunction, perform the “Circuit Open/Short Inspection”.

Circuit Open/Short Inspection

PSP SWITCH
WIRING HARNESS-SIDE CONNECTOR

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00000939

1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

2. Inspect the following wiring harness for open or short. (Continuity inspection)

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
— PSP switch terminal A and PCM terminal 2I

Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
— PSP switch terminal A and body ground
End Of Sie
WM: MASS AIR FLOW SENSOR

01-40–8
1890-1U-06H(01-40).fm 9 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION [MZI-3.5]
id0140c1805500
1. Disconnect the negative battery cable.
2. Disconnect MAF/IAT sensor connector.
3. Remove the MAF/IAT sensor.
4. Install in the reverse order of removal.
End Of Sie
01-40

MAF/IAT SENSOR

1.16—1.76 N·m
{11.9—11.9 kgf·m, 10.3—15.5 ft·lbf}

ac9uuw00000430

MASS AIR FLOW (MAF) SENSOR INSPECTION [MZI-3.5]

id0140c1800700

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)

Visual Inspection
1. Verify the following items of the MAF sensor.
• Damage, cracks
• Rusted sensor terminal
• Bent sensor terminal
— If there is any malfunction, replace the MAF sensor. (See 01-40-9 MASS AIR FLOW (MAF)/INTAKE
AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION [MZI-3.5].)

Voltage Inspection
1. Remove the MAF sensor with the connector still connected.
2. Turn the ignition switch to the ON position.
3. Verify that the MAF sensor output voltage (M-MDS monitor item: MAF) changes when wind is introduced
gradually to the sensor part of the MAF sensor.
• If it cannot be verified even though the related harnesses have no malfunction, replace the MAF sensor.
(See 01-40-9 MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/
INSTALLATION [MZI-3.5].)
• If the monitor item status/specification (reference) is not within the specification, even though the resistance
is within the specification, perform the “Circuit Open/Short Inspection“.

01-40–9
1890-1U-06H(01-40).fm 10 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Circuit Open/Short Inspection

MAF/IAT SENSOR FUSE BOX

WIRING HARNESS-SIDE CONNECTOR (MAIN RELAY NO.1)

A E

C
F E D C B A
D

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

ac9uuw00000940

1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

2. Disconnect the MAF/IAT sensor connector.
3. Inspect the following wiring harnesses for open or short. (Continuity inspection)

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
— MAF/IAT sensor terminal A and main relay No.1 terminal D
— MAF/IAT sensor terminal C and PCM terminal 1AJ
— MAF/IAT sensor terminal D and PCM terminal 1AN
— MAF/IAT sensor terminal E and PCM terminal 1AL

Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
— MAF/IAT sensor terminal A and body ground
— MAF/IAT sensor terminal C and power supply
— MAF/IAT sensor terminal C and body ground
— MAF/IAT sensor terminal D and power supply
— MAF/IAT sensor terminal D and body ground
— MAF/IAT sensor terminal E and power supply
End Of Sie
WM: INTAKE AIR TEMPERATURE SENSOR

01-40–10
1890-1U-06H(01-40).fm 11 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [MZI-3.5]
id0140c1802200

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)

Resistance Inspection
1. Disconnect the MAF/IAT sensor connector. 01-40
2. Measure the resistance between MAF/IAT sensor
terminals A and F.
• If not within the specification, replace the
MAF/IAT sensor. (See 01-40-9 MASS AIR
FLOW (MAF)/INTAKE AIR TEMPERATURE F E D C B A
(IAT) SENSOR REMOVAL/INSTALLATION
[MZI-3.5].)
• If the monitor item status/specification
(reference) is not within the specification,
even though the resistance is within the
specification, perform the “Circuit Open/Short
Inspection”.
ac9uuw00001094

IAT sensor resistance

IAT (°C {°F}) Resistance (kilohm)
10 {50} Approx. 58.75
20 {68} Approx. 37.30
30 {86} Approx. 24.27
60 {140} Approx. 7.70

IAT sensor characteristics graph (reference)

70
60
50
RESISTANCE

40
(KILOHM)

30
20
10
0
20 40 60 80 100
{68} {104} {140} {176} {212}
TEMPERATURE (°C {°F})
atraaw00000197

01-40–11
1890-1U-06H(01-40).fm 12 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Circuit Open/Short Inspection

MAF/IAT SENSOR
WIRING HARNESS-SIDE CONNECTOR

F E D C B A

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

ac9uuw00000951

1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

2. Inspect the following wiring harnesses for open or short. (Continuity inspection)

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
— MAF/IAT sensor terminal B and body ground
— MAF/IAT sensor terminal F and PCM terminal 1AF

Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
— MAF/IAT sensor terminal B and power supply
— MAF/IAT sensor terminal F and body ground
— MAF/IAT sensor terminal F and power supply
End Of Sie
THROTTLE POSITION (TP) SENSOR INSPECTION [MZI-3.5]
WM: THROTTLE POSITION SENSOR

id0140c1802700

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)

01-40–12
1890-1U-06H(01-40).fm 13 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Voltage Inspection
1. Verify that no DTC related to APP sensor has been detected.
• If any DTCs related to APP sensor have been detected, perform the DTC inspection. (See 01-02-12 DTC
TABLE [MZI-3.5].)
2. Connect the M-MDS to the DLC-2.
3. Turn the ignition switch to the ON position.
4. Select TP1 or TP2 PID (voltage) on the M-MDS.
01-40

DLC-2

ac9uuw00001450
5. Operate the accelerator pedal and verify that the
TP1 or TP2 PID (voltage) changes as shown in 5

TP OUTPUT VOLTAGE
the following graph. TP2
• If not verified, perform the “Circuit Open/Short
Inspection”.
— If there is no open or short circuit, replace
the throttle body. (See 01-13-4 INTAKE-
AIR SYSTEM REMOVAL/INSTALLATION
[MZI-3.5].) 0 TP1
0° 83°
THROTTLE ANGLE (DEGREES)
ac9uuw00002506
Circuit Open/Short Inspection

THROTTLE BODY
WIRING HARNESS-SIDE CONNECTOR

F E D C B A

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00000964

1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

2. Inspect the following wiring harnesses for open or short circuit. (Continuity inspection)

01-40–13
1890-1U-06H(01-40).fm 14 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Throttle body terminal C and PCM terminal 2AD
— Throttle body terminal D and PCM terminal 2D
— Throttle body terminal E and PCM terminal 2AH
— Throttle body terminal F and PCM terminal 2Z

Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Throttle body terminal C and power supply
— Throttle body terminal C and body ground
— Throttle body terminal D and body ground
— Throttle body terminal E and power supply
— Throttle body terminal F and body ground
— Throttle body terminal F and power supply
End Of Sie
ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZI-3.5]
WM: ACCELERATOR PEDAL POSITION SENSOR

id0140c1803200

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)

Voltage Inspection
1. Turn the ignition switch to the ON position (Engine OFF).
2. Verify that the PCM terminal 1AC, 1AG and 1AK change smoothly while throttle valve is gradually opened.
• If as verified, go to next step.
• If not as verified, perform the “Circuit Open/Short Inspection”.
— If there is no open or short circuit, replace the throttle body.
3. Verify that the PCM terminal 1AC, 1AG and 1AK voltages are as shown in the following table.
PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

ac9uuw00000981

• If voltage is not as following table, perform the “Circuit Open/Short Inspection”.

— If there is no open or short circuit, replace accelerator pedal. (See 01-13-8 ACCELERATOR PEDAL
REMOVAL/INSTALLATION [MZI-3.5].)

APP sensor output voltage

PCM terminal 1AK PCM terminal 1AG PCM terminal 1AC
Condition
(APP sensor No.1) (APP sensor No.2) (APP sensor No.3)
Accelerator
Approx. 4.1 V Approx. 1.5 V Approx. 0.1 V
pedal released
Accelerator
Approx. 1.0 V Approx. 3.9 V Approx. 3.3 V
pedal depressed

01-40–14
1890-1U-06H(01-40).fm 15 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Circuit Open/Short Inspection

ACCELERATOR PEDAL POSITION SENSOR

WIRING HARNESS-SIDE CONNECTOR

G E C A

H F D B
01-40

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

ac9uuw00000982

1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

2. Inspect the following wiring harnesses for open or short circuit. (Continuity inspection)

Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— APP sensor terminal B and PCM terminal 1AC
— APP sensor terminal C and PCM terminal 1AH
— APP sensor terminal D and PCM terminal 1Y
— APP sensor terminal E and PCM terminal 1AK
— APP sensor terminal F and PCM terminal 1BA
— APP sensor terminal G and PCM terminal 1AD

Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— APP sensor terminal B and body ground
— APP sensor terminal B and power supply
— APP sensor terminal C and power supply
— APP sensor terminal D and body ground
— APP sensor terminal E and body ground
— APP sensor terminal E and power supply
— APP sensor terminal F and body ground
— APP sensor terminal G and power supply
End Of Sie
WM: CRANKSHAFT POSITION PLATE

01-40–15
1890-1U-06H(01-40).fm 16 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZI-3.5]
id0140c1800600

Note
• Disconnect the connector after the CKP sensor is removed to prevent the CKP sensor from falling off.
• The bolt and sensor are integrated and cannot be pulled out.
• When removing the CKP sensor, be careful not to drop the tool.
• The bolt and sensor must be pulled in
different directions. Pull them as indicated in
the figure.
CKP SENSOR

ac9uuw00000460

Removal
1. Disconnect the negative battery cable.
2. Remove the following part for easier access.
1. Remove the Catalytic Converter (WU-TWC) (LH).(See 01-15-1 EXHAUST SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
3. Remove in the order indicated in the table.
1 Insulator
2 Cover
8.9—12.1 {91—123,
3 CKP sensor 79—107}
4 CKP sensor connector 4 1
3
4. Install in the reverse order of removal.
End Of Sie
8.9—12.1 {91—123,
2 79—107}

N·m {kgf·m, in·lbf}

ac9uuw00000461

01-40–16
1890-1U-06H(01-40).fm 17 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZI-3.5]
id0140c1800500

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
Visual Inspection
1. Remove the CKP sensor. (See 01-40-16 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/
INSTALLATION [MZI-3.5].) 01-40
2. Verify that there are no metal shavings on the CKP sensor.
3. Install the CKP sensor. (See 01-40-16 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION
[MZI-3.5].)
Resistance Inspection
1. Remove the CKP sensor connector.
2. Measure the resistance between the CKP sensor terminals.
• If not within the specification, replace the CKP sensor. (See 01-40-16 CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION [MZI-3.5].)
• If the monitor item status/specification (reference) is not within the specification, even though the resistance
is within the specification, perform the “Circuit Open/Short Inspection”.

CKP sensor resistance

250—1,000 ohms

Circuit Open/Short Inspection

CKP SENSOR
HARNESS SIDE CONNECTOR

B A

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00000985
1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
2. Inspect the following harness for open or short circuit. (Continuity check)

Open circuit
• CKP sensor terminal A and PCM terminal 2P
• CKP sensor terminal B and PCM terminal 2T

Short circuit
• CKP sensor terminal A and power supply
• CKP sensor terminal A and body ground
• CKP sensor terminal B and power supply
• CKP sensor terminal B and body ground

01-40–17
1890-1U-06H(01-40).fm 18 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

End Of Sie

CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZI-3.5]

WM: CAMSHAFT POSITION SENSOR

id0140c1801500
1. Disconnect the negative battery cable.
2. Remove the battery.
3. Remove the following part for easier access.
• Remove the resonance chamber and air cleaner assy. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
4. Disconnect the CMP sensor connector
5. Remove the CMP sensor.
CMP SENSOR(LH) CMP SENSOR(RH)
Note
• Lubricate the CMP O-ring seal with clean
engine oil.

6. Install in the reverse order of removal.

End Of Sie

7.8—10.8 N·m
{80—110 kgf·cm,
70—85 in·Ibf}

ac9uuw00000431

CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZI-3.5]

id0140c1801400

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)

Visual Inspection
1. Remove the CMP sensor. (See 01-40-18 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION
[MZI-3.5].)
2. Verify that there are no metal shavings on the CMP sensor.
3. Install the CMP sensor. (See 01-40-18 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION
[MZI-3.5].)

Resistance Inspection
1. Remove the CMP sensor connector.
2. Measure the resistance between the CMP sensor terminals.
• If not within the specification, replace the CMP sensor. (See 01-40-18 CAMSHAFT POSITION (CMP)
SENSOR REMOVAL/INSTALLATION [MZI-3.5].)
• If the monitor item status/specification (reference) is not within the specification, even though the resistance
is within the specification, perform the “Circuit Open/Short Inspection”.

CMP sensor resistance

250—1,000 ohms

01-40–18
1890-1U-06H(01-40).fm 19 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Circuit Open/Short Inspection

CMP SENSOR
HARNESS SIDE CONNECTOR

B A

01-40

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00000987

1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

2. Inspect the following harness for open or short circuit. (Continuity check)

Open circuit
• CMP sensor (RH) terminal A and PCM terminal 2X
• CMP sensor (RH) terminal B and PCM terminal 2C
• CMP sensor (LH) terminal A and PCM terminal 2AB
• CMP sensor (LH) terminal B and PCM terminal 2C

Short circuit
• CMP sensor (RH) terminal A and power supply
• CMP sensor (RH) terminal A and body ground
• CMP sensor (RH) terminal B and power supply
• CMP sensor (LH) terminal A and power supply
• CMP sensor (LH) terminal A and body ground
• CMP sensor (LH) terminal B and power supply
End Of Sie
WM: HEATED OXYGEN SENSOR

01-40–19
1890-1U-06H(01-40).fm 20 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZI-3.5]
id0140c1804800
HO2S (LH) Removal/Installation
1. Disconnect the negative battery cable.
2. Remove the engine cover. (See 01-10-3 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5].)
3. Disconnect the HO2S (LH) connector.

Note
• If necessary, lubricate the HO2S with Penetrating and Lock Lubricant loosen to aid in removal.

4. Remove the HO2S (LH) using the SST.

Note
• Apply a light coat of anti-seize lubricant to
the threads of the HO2S.
SST *
5. Install in the reverse order of removal. 40.3—54.7
{4.11—5.57, 29.8—40.3}

*
SST SST (49 L018 001) N·m {kgf·m, ft·lbf}
ac9uuw00000470

HO2S (RH) Removal/Installation

1. Disconnect the negative battery cable.
2. Remove the following part for easier access.
1. Remove the cowl panel. (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
3. Disconnect the HO2S (RH) connector.

Note
• If necessary, lubricate the HO2S with Penetrating and Lock Lubricant loosen to aid in removal.

4. Remove the HO2S (RH) using the SST.

Note
• Apply a light coat of anti-seize lubricant to
the threads of the HO2S.
SST *
5. Install in the reverse order of removal. 40.3—54.7
End Of Sie {4.11—5.57, 29.8—40.3}

*
SST SST (49 L018 001) N·m {kgf·m, ft·lbf}
ac9uuw00000485

01-40–20
1890-1U-06H(01-40).fm 21 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION [MZI-3.5]
id0140c1804700

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
Front Heated Oxygen Sensor (HO2S) Voltage Inspection
1. Warm up the engine to normal operating temperature.
2. Using the M-MDS, monitor the following: 01-40
— Vehicle speed (PID: VSS)
— Engine speed (PID: RPM)
— Front HO2S voltage (PID: O2S11, O2S21)
3. Drive the vehicle and decelerate the engine speed by releasing the accelerator pedal fully when the engine
speed is 3,000 rpm or more.
4. Verify that the front HO2S outputs a voltage of 0.6 V or more, one time or more, then verify that the front HO2S
voltage (PID: O2S11, O2S21) is 0.3 V is or less while decelerating as shown in the figure.

VSS

0 KPH

3000 RPM

2000 RPM
RPM
1000 RPM

0 RPM

1V

O2S11, 0.5V
O2S21 0.3V OR LESS

0V
atraaw00003393
• If not within the specification, inspect the front HO2S for an open or short circuit. (See 01-40-21 Front
Heated Oxygen Sensor (HO2S) Voltage Inspection.) Then if there is no malfunction in the wiring harness,
replace the front HO2S. (See 01-40-20 FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/
INSTALLATION [MZI-3.5].)
HO2S Heater Resistance Inspection
1. Disconnect the HO2S connector.
2. Measure the resistance between HO2S terminals
C and A.
• If it is not within the specification, replace the
HO2S. (See 01-40-20 FRONT HEATED
OXYGEN SENSOR (HO2S) REMOVAL/
INSTALLATION [MZI-3.5].)
• If the monitor item status/specification C A

(reference) is not within the specification, D B

even though the resistance is within the
specification, perform the “Circuit Open/Short
Inspection”.

HO2S heater resistance

3—30 ohms

ac9uuw00001096

01-40–21
1890-1U-06H(01-40).fm 22 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
2. Inspect the following wiring harness for open or short (continuity check).
FRONT HO2S SENSOR

FUSE BOX
(MAIN RELAY NO.2)

C A
A E
D B
C

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00001000

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
— HO2S (RH) terminal A and PCM terminal 2J
— HO2S (RH) terminal B and PCM terminal 2Y
— HO2S (RH) terminal C and main relay No.2 terminal D
— HO2S (RH) terminal D and PCM terminal 2AL
— HO2S (LH) terminal A and PCM terminal 2E
— HO2S (LH) terminal B and PCM terminal 2U
— HO2S (LH) terminal C and main relay No.2 terminal D
— HO2S (LH) terminal D and PCM terminal 2AL

Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the harness.
— HO2S (RH) terminal A and power supply
— HO2S (RH) terminal A and body ground
— HO2S (RH) terminal B and power supply
— HO2S (RH) terminal B and body ground
— HO2S (RH) terminal C and body ground
— HO2S (RH) terminal D and power supply
— HO2S (LH) terminal A and power supply
— HO2S (LH) terminal A and body ground
— HO2S (LH) terminal B and power supply
— HO2S (LH) terminal B and body ground
— HO2S (LH) terminal C and body ground
— HO2S (LH) terminal D and power supply
End Of Sie

01-40–22
1890-1U-06H(01-40).fm 23 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZI-3.5]
id0140c1805000
HO2S (LH) Removal/Installation
1. Disconnect the negative battery cable.
2. Disconnect the HO2S (LH) connector.

Note
• If necessary, lubricate the HO2S (LH) with Penetrating and Lock Lubricant loosen to aid in removal.
01-40
3. Remove the HO2S (LH) using the SST.

Note
• Apply a light coat of anti-seize lubricant to
the threads of the HO2S.

4. Install in the reverse order of removal. *

SST
40.3—54.7
{4.11—5.57, 29.8—40.3}
* SST (49 L018 001)
SST N·m {kgf·m, ft·lbf}

ac9uuw00000471

HO2S (RH) Removal/Installation

1. Disconnect the negative battery cable.
2. Remove the following part for easier access.
1. Remove the cowl panel. (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
3. Disconnect the HO2S (RH) connector.

Note
• If necessary, lubricate the HO2S (RH) with Penetrating and Lock Lubricant loosen to aid in removal.

4. Remove the HO2S (RH) using the SST.

Note
• Apply a light coat of anti-seize lubricant to
the threads of the HO2S.

5. Install in the reverse order of removal.

End Of Sie SST *
40.3—54.7
{4.11—5.57, 29.8—40.3}
*
SST SST (49 L018 001) N·m {kgf·m, ft·lbf}
ac9uuw00000486

REAR HEATED OXYGEN SENSOR (HO2S) INSPECTION [MZI-3.5]

id0140c1804900

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)

Rear Heated Oxygen Sensor (HO2S) Voltage Inspection

1. Warm up the engine to normal operating temperature.
2. Using the M-MDS, monitor the following:
— Vehicle speed (PID: VSS)
— Engine speed (PID: RPM)
— Rear HO2S voltage (PID: O2S12, O2S22)
3. Drive the vehicle and decelerate the engine speed by releasing the accelerator pedal fully when the engine
speed is 3,000 rpm or more.

01-40–23
1890-1U-06H(01-40).fm 24 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

4. Verify that the rear HO2S outputs a voltage of 0.6 V or more, one time or more, then verify that the rear HO2S
voltage (PID: O2S12, O2S22) is 0.3 V is or less while decelerating as shown in the figure.

VSS

0 KPH

3000 RPM

2000 RPM
RPM
1000 RPM

0 RPM

1V

O2S12, 0.5V
O2S22 0.3V OR LESS

0V
atraaw00003394

• If not within the specification, inspect the rear HO2S for an open or short circuit. Then if there is no
malfunction in the wiring harness, replace the rear HO2S. (See 01-40-23 REAR HEATED OXYGEN
SENSOR (HO2S) REMOVAL/INSTALLATION [MZI-3.5].)

HO2S Heater Resistance Inspection

1. Disconnect the HO2S connector.
2. Measure the resistance between HO2S terminals
C and A.
• If it is not within the specification, replace the
HO2S. (See 01-40-23 REAR HEATED
OXYGEN SENSOR (HO2S) REMOVAL/
INSTALLATION [MZI-3.5].)
• If the monitor item status/specification C A
(reference) is not within the specification, D B
even though the resistance is within the
specification, perform the “Circuit Open/Short
Inspection”.

HO2S heater resistance

3⎯30 ohms

ac9uuw00001097

01-40–24
1890-1U-06H(01-40).fm 25 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
2. Inspect the following wiring harness for open or short (continuity check).
REAR HO2S SENSOR

FUSE BOX
(MAIN RELAY NO.2) 01-40
C A
D B A E

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00001002

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
— HO2S (RH) terminal A and PCM terminal 2AS
— HO2S (RH) terminal B and PCM terminal 2BG
— HO2S (RH) terminal C and main relay No.2 terminal D
— HO2S (RH) terminal D and PCM terminal 2AL
— HO2S (LH) terminal A and PCM terminal 2AO
— HO2S (LH) terminal B and PCM terminal 2BC
— HO2S (LH) terminal C and main relay No.2 terminal D
— HO2S (LH) terminal D and PCM terminal 2AL

Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the harness.
— HO2S (RH) terminal A and power supply
— HO2S (RH) terminal A and body ground
— HO2S (RH) terminal B and power supply
— HO2S (RH) terminal B and body ground
— HO2S (RH) terminal C and body ground
— HO2S (RH) terminal D and power supply
— HO2S (LH) terminal A and power supply
— HO2S (LH) terminal A and body ground
— HO2S (LH) terminal B and power supply
— HO2S (LH) terminal B and body ground
— HO2S (LH) terminal C and body ground
— HO2S (LH) terminal D and power supply
End Of Sie
WM: KNOCK SENSOR

01-40–25
1890-1U-06H(01-40).fm 26 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

KNOCK SENSOR (KS) REMOVAL/INSTALLATION [MZI-3.5]
id0140c1802900

Note
• Put a tray under the converter housing to receive the engine coolant.

1. Disconnect the negative battery cable.

2. Remove the following part for easier access.
Perform the following procedure to remove the
intake manifold
1. Remove the ventilation hose. (See 01-16-
15 QUICK RELEASE CONNECTOR
(EMISSION SYSTEM) REMOVAL/
INSTALLATION [MZI-3.5].)
2. Remove the vacuum hose (to purge
solenoid valve). (See 01-16-15 QUICK
RELEASE CONNECTOR (EMISSION
SYSTEM) REMOVAL/INSTALLATION
[MZI-3.5].)
3. Remove the fuel hose. (See 01-14-22
QUICK RELEASE CONNECTOR (FUEL
SYSTEM) REMOVAL/INSTALLATION
[MZI-3.5].)
4. Remove the fuel distributor. (See 01-14- TRAY
23 FUEL INJECTOR REMOVAL/
INSTALLATION [MZI-3.5].)
5. Remove the intake manifold. (See 01-13-
4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].) ac9uuw00000464

3. Remove in the order indicated in the table.

1 Water inlet pipe
2 O-ring 2 R
3 KS connector
1
4 KS
16.2—23.8 N·m
{1.66—2.42 kgf·m,
Note 12.0—17.5 ft·lbf}
• Lubricate the new O-ring with clean engine
coolant for installation. 3
4
4. Install in the reverse order of removal.
End Of Sie

ac9uuw00000465

01-40–26
1890-1U-06H(01-40).fm 27 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

KNOCK SENSOR (KS) INSPECTION [MZI-3.5]
id0140c1802800

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
Resistance Inspection
1. Turn the ignition switch to LOCK.
2. Disconnect the KS connector. 01-40
3. Measure the resistance between the KS terminals.
KS(RH): KS terminals A and B
KS(LH): KS terminals C and D
• If not as specified, replace the KS.
• If the KS is normal, but PID value is out of specification, perform the “Circuit Open/Short Inspection”.
KS resistance
4.39—5.35 Mohms
Circuit Open/Short Inspection
KS
WIRING HARNESS-SIDE CONNECTOR

A B C D

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00000993
1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)
2. Inspect the following wiring harnesses for open or short. (Continuity inspection)
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
— KS terminal A and PCM terminal 2Q
— KS terminal B and PCM terminal 2M
— KS terminal C and PCM terminal 2L
— KS terminal D and PCM terminal 2G
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
— KS terminal A and power supply
— KS terminal A and body ground
— KS terminal B and power supply
— KS terminal B and body ground
— KS terminal C and power supply
— KS terminal C and body ground
— KS terminal D and power supply
— KS terminal D and body ground
01-40–27
1890-1U-06H(01-40).fm 28 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

End Of Sie

CYLINDER HEAD TEMPERATURE (CHT) SENSOR REMOVAL/INSTALLATION [MZI-3.5]

WM: CYLINDER HEAD TEMPERATURE SENSOR

id0140c1889800

Note
• Do not reuse the CHT sensor, install a new sensor.

1. Disconnect the negative battery cable.

2. Remove the following part for easier access.
Perform the following procedure to remove the intake manifold.
1. Remove the ventilation hose. (See 01-16-15 QUICK RELEASE CONNECTOR (EMISSION SYSTEM)
REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the vacuum hose (to purge solenoid valve). (See 01-16-15 QUICK RELEASE CONNECTOR
(EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the fuel hose. (See 01-14-22 QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/
INSTALLATION [MZI-3.5].)
4. Remove the fuel distributor. (See 01-14-23 FUEL INJECTOR REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the intake manifold. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Disconnect the CHT sensor connector.
5. Remove the CHT sensor using the following tools.
• Socket
3/8", 20mm, 6point
• Ratchet handle and torque wrench
3/8" Drive

ac9uuw00000466

6. Install in the reverse order of removal.

Tightening torque
10 N·m {102 kgf·cm, 89 in·lbf}

End Of Sie

ac9uuw00000467

CYLINDER HEAD TEMPERATURE (CHT) SENSOR INSPECTION [MZI-3.5]

id0140c1889900

Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)

Resistance Inspection
1. Disconnect the CHT sensor connector.
2. Measure the resistance between the CHT sensor terminals.
• If it is not within the specification, replace the CHT sensor.
• If the monitor item status/specification (reference) is not within the specification, even though the resistance
is within the specification, perform the “Circuit Open/Short Inspection”.

Measure the cylinder head temperature sensor resistance (approx.).

Cylinder head temperature
Resistance (kilohm)
(°C {°F})
20 {68} 37.387
80 {176} 3.775

01-40–28
1890-1U-06H(01-40).fm 29 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

Cylinder head temperature sensor characteristics graph (reference)
70
60
50

RESISTANCE
40

(KILOHM)
30
20
10 01-40
0 40 60 80 100
20
{68} {104} {140} {176} {212}
TEMPERATURE (˚C {˚F})
ac9uuw00000141

Circuit Open/Short Inspection

CHT SENSOR
WIRING HARNESS-SIDE CONNECTOR

A B

PCM
WIRING HARNESS-SIDE CONNECTOR

2BQ 2BL 2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2F 2A

2BN 2BI 2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2H 2C

2BR 2BM 2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2G 2B

2BO 2BJ 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2I 2D

2BP 2BK 2J 2E

ac9uuw00000989

1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

2. Inspect the following wiring harnesses for open or short. (Continuity inspection)

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
— CHT sensor terminal A and PCM terminal 2AL
— CHT sensor terminal B and PCM terminal 2AN

Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
— CHT sensor terminal A and power supply
— CHT sensor terminal A and body ground
— CHT sensor terminal B and power supply
End Of Sie
WM: FUEL PRESSURE SENSOR

01-40–29
1890-1U-06H(01-40).fm 30 ページ ２００６年１２月１９日　火曜日　午前１０時５８分

CONTROL SYSTEM [MZI-3.5]

FUEL TANK PRESSURE SENSOR INSPECTION [MZI-3.5]
id0140c1857400
Voltage Inspection
1. Remove the evaporative hose component. (See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-3.5].)
2. Turn the ignition switch to the ON position.
3. Plug one end of the evaporative hose component and verify that the output voltage from the fuel tank pressure
sensor changes when pressure is applied from the other hose end.
• If it cannot be verified even though the related harnesses have no malfunction, replace the evaporative
hose component.(See 01-14-8 FUEL TANK REMOVAL/INSTALLATION [MZI-3.5].)
• If the monitor item status/specification (reference) is not within the specification, even though the resistance
is within the specification, perform the “Circuit Open/Short Inspection“.

Circuit Open/Short Inspection

FUEL TANK PRESSURE SENSOR

WIRING HARNESS-SIDE CONNECTOR

C B A

PCM
WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

ac9uuw00001131

1. Disconnect the PCM connector. (See 01-40-4 PCM REMOVAL/INSTALLATION [MZI-3.5].)

2. Disconnect the fuel tank pressure sensor connector.
3. Inspect the following wiring harnesses for open or short. (Continuity inspection)

Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
— Fuel tank pressure sensor terminal A and PCM terminal 1AB
— Fuel tank pressure sensor terminal B and PCM terminal 1AL
— Fuel tank pressure sensor terminal C and PCM terminal 1U

Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
— Fuel tank pressure sensor terminal A and power supply
— Fuel tank pressure sensor terminal A and body ground
— Fuel tank pressure sensor terminal B and power supply
— Fuel tank pressure sensor terminal C and body ground
End Of Sie

01-40–30
 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
TECHNICAL DATA [MZI-3.5]
01-50 TECHNICAL DATA [MZI-3.5]
ENGINE TECHNICAL DATA
[MZI-3.5] . . . . . . . . . . . . . . . . . . . . . . . . 01-50–1

End of Toc
ENGINE TECHNICAL DATA [MZI-3.5]
WM: ENGINE

id0150d1800100 01-50
Item Specification
IN: 0.150—0.250 mm {0.00591—0.00984 in}
Standard valve clearance [Engine cold]
EX: 0.300—0.400 mm {0.0119—0.0157 in}
Oil control valve resistance 5—14 ohms
Ignition timing Approx. BTDC 13 °
No load: 570—670 rpm
Electrical load on: 630—730 rpm
Idle speed (P position)
Power steering oil pump operation: 600—700 rpm
A/C and heater operation: 570—850 rpm [-40—49 °C {-40—120 °F}]
HC concentration: Within the regulation
Idle mixture
CO concentration: Within the regulation
Oil replacement: 4.7 L {5.0 US qt, 4.2 Imp qt}
Engine oil capacity (approx. quantity)
Oil and oil filter replacement: 5.2 L {5.5 US qt, 4.6 Imp qt}
Oil pressure (reference value) [oil temperature: 93.3
°C {200 °F}] 310—621 kPa {3.17—6.33 kgf/cm2, 45.0—90.0 psi} [2,000 rpm]
Dual fan control module: 11.7 L {12.4 US qt, 10.3 Imp qt}
Engine coolant capacity (approx. quantity)
Single fan control module: 11.1 L {11.7 US qt, 9.77 Imp qt}
Cooling system cap valve opening pressure 93.2—122.6 kPa {0.95—1.25 kgf/cm2, 13.5—17.8 psi}
Thermostat initial-opening temperature 79.5—83.3 °C {175.2—181.9 °F}
Thermostat full-open temperature 94.5 °C {202.1 °F}
Thermostat full-open lift More than 8.1 mm {0.32 in}
Cooling fan motor standard current [Single fan control
No.1, No.2: 11.2—15.2 A
module]
Cooling fan motor standard current [Dual fan control
No.1, No.2: 17—23 A
module]
Fuel line pressure 331—485 kPa {3.38—4.94 kgf/cm2, 48.1—70.3 psi}
Fuel injector resistance 11—18 ohms

Battery electrolyte specific gravity [20 °C {68 °F}] 1.22—1.29

Battery load test current 80D26L (55): 195 A
Vehicles with immobilizer system: 50—60 mA
Battery back-up current
Vehicles without immobilizer system: 55 mA or less
Battery slow charge current 80D26L (55): 5.5—6.5 A
Battery quick charge current [30 min] 80D26L (55): 35 A
Terminal B: B+
Terminal A: B+
Generator standard voltage [IG-ON]
Terminal RC: Approx. 1 V or less
Terminal LI: Approx. 1 V
Terminal B: 12—16 V
Terminal A: 12—16 V
Generator standard voltage [Idle, 20 °C {68 °F}]
Terminal RC: 0—16 V
Terminal LI: 1—16 V
70 % of the nominal output current (nominal output current: 110 A)
Generator generated current minimum value [Ambient temp. 20 °C {68 °F}, voltage 13.0—15.0 V, both engine and
generator are hot]
Generator rotor resistance (between slip rings) [20 °C
1.8—2.2 ohm
{68 °F}]
Standard: 22.5 mm {0.89 in}
Generator brush length
Minimum: 5.0 mm {0.20 in}
Standard: 4.1—5.3 N {0.42—0.54 kgf, 0.92—1.19 lbf}
Generator brush spring force
Minimum: 1.7 N {0.17 kgf, 0.38 lbf}
Ignition coil secondary coil resistance 5—6 kilohms

Revised 1/2007 (Ref. No. R009/07) 01-50–1

 2007 Mazda CX-9 Workshop Manual (1890–1U–06L)
TECHNICAL DATA [MZI-3.5]
Item Specification
1-4-2-5-3-6
CYLINDER No.
CRANKSHAFT
PULLEY ENGINE

Firing order 4 1

5 2
6 3

LH RH
Spark plug type ZZJ1 18 110
Spark plug gap 1.29—1.45 mm {0.051—0.057 in}
Spark plug resistance 2—20 kilohms
Starter no-load test voltage 11 V
Starter no-load test current 90 A or less
Starter pinion gap 0 mm {0 in}
Starter armature runout 0.1 mm {0.004 in} max.
Standard: 29.4 mm {1.16 in}
Starter commutator diameter
Minimum: 28.8 mm {1.13 in}
Standard: 0.5 mm {0.02 in}
Segment groove depth of starter commutator
Minimum: 0.2 mm {0.008 in}
Standard: 12.3 mm {0.48 in}
Starter brush length
Minimum: 5.5 mm {0.22 in}
Standard: 15.0—20.4 N {1.53—2.08 kgf, 3.38—4.58 lbf}
Starter brush spring force
Minimum: 2.75 N {0.28 kgf, 0.62 lbf}

Engine oil specification

Item U.S.A. and CANADA Except U.S.A. and CANADA
SM

Engine oil grade

(ILSAC) (ILSAC)

API SM or ILSAC
Engine oil viscosity 5W-20

End Of Sie

01-50–2
1890-1U-06H(01-60).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時０分

SERVICE TOOLS [MZI-3.5]

01-60 SERVICE TOOLS [MZI-3.5]
ENGINE SST [MZI-3.5] . . . . . . . . . . . . . . 01-60–1

End of Toc
ENGINE SST [MZI-3.5]
WM: ENGINE

id0160d1800100
1: Mazda SST number 01-60
2: Global SST number
Example
1: 49 UN01 002
2: 303-102

Crankshaft
damper
replacer

1: 49 C017 5A0 1: 49 L017 5A0 1: 49 UN01 002

2: – 2: – 2: 303-102

Engine support Support hanger Crankshaft

set damper
replacer

1: 49 G028 203 1: 49 UN30 1: 49 G033 102

2: – 3D1210 2: –
2: 303-D121
Support Handle
(Component Puller
part of 49 F034
2A0)
1: 49 G033 105 1: 49 W026 001 1: 49 UN30
2: – 2: – 312480
2: 303-1248
Attachment Oil seal installer
Hold

1: 49 W011 101 1: 49 UN30 1: 49 UN30

2: – 312523 312521
2: – 2: –
Oil seal installer
Installer Remover
(Component (Component
part of 49 UN30 part of 49 UN30
3125A0) 3125A0)
1: 49 N013 1: 49 T013 101 1: 49 L018 001
101A 2: – 2: –
2: –
Hose O2 sensor
Body wrench
(Component
part of 49 N013
1A0D)
1: 49 0107 1: 49 L010 1A0 1: 49 0187
680A 2: – 280A
2: – 2: –
Engine hanger
Engine stand set Oil pressure
gauge

01-60–1
1890-1U-06H(01-60).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時０分

SERVICE TOOLS [MZI-3.5]

1: 49 T018 006 1: 49 T018 007 1: 49 9200 145
2: – 2: – 2: –

Hose Adapter Radiator cap

tester adapter
set

1: 49 B019 1: –
901B 2: 134-01049
2: –
Evaporative
Oil pressure emission –
gauge system tester
(Component
part of 49 N013
1A0D)

End Of Sie

01-60–2
1890-1U-06H(02-02).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時１分

SUSPENSION 02SECTION

Toc of SCT
ON-BOARD DIAGNOSTIC . . . . 02-02 WHEEL AND TIRES. . . . . . . . . 02-12
02-02
SYMPTOM FRONT SUSPENSION . . . . . . . 02-13
TROUBLESHOOTING . . . . . . 02-03 REAR SUSPENSION . . . . . . . . 02-14
GENERAL PROCEDURES . . . . 02-10 TECHNICAL DATA . . . . . . . . . . 02-50
WHEEL ALIGNMENT . . . . . . . . 02-11 SERVICE TOOLS . . . . . . . . . . . 02-60
Toc of SCT
02-02 ON-BOARD DIAGNOSTIC
TIRE PRESSURE MONITORING Freeze Frame PID Data
SYSTEM (TPMS) Access Procedure . . . . . . . . . . . . . . . 02-02–4
WIRING DIAGRAM. . . . . . . . . . . . . . . . . 02-02–2 DTC Table . . . . . . . . . . . . . . . . . . . . . . 02-02–5
With Advanced Keyless System . . . . . . 02-02–2 PID/DATA Monitor Table . . . . . . . . . . . . 02-02–5
With Keyless Entry System . . . . . . . . . . 02-02–2 Active Command Modes Table. . . . . . . 02-02–6
TIRE PRESSURE MONITORING MALFUNCTIONING WHEEL
SYSTEM (TPMS) ON-BOARD UNIT IDENTIFICATION . . . . . . . . . . . . . 02-02–6
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 02-02–3 DTC B2143 . . . . . . . . . . . . . . . . . . . . . . . 02-02–7
On-Board Diagnostic (OBD) DTC B2868, B2869, B2870,
Test Description . . . . . . . . . . . . . . . . . 02-02–3 B2871. . . . . . . . . . . . . . . . . . . . . . . . . . . 02-02–8
Reading DTCs Procedure . . . . . . . . . . . 02-02–3 DTC U0127 . . . . . . . . . . . . . . . . . . . . . . . 02-02–9
Clearing DTCs Procedures . . . . . . . . . . 02-02–3 With Advanced Keyless
PID/Data Monitor and System . . . . . . . . . . . . . . . . . . . . . . . . 02-02–9
Record Procedure . . . . . . . . . . . . . . . . 02-02–4 With Keyless Entry System . . . . . . . . . 02-02–10
Active Command Modes DTC U2616, U2617, U2618,
Procedure . . . . . . . . . . . . . . . . . . . . . . 02-02–4 U2619. . . . . . . . . . . . . . . . . . . . . . . . . . . 02-02–11

End of Toc
WM: TIRE PRESSURE MONITORING SYSTEM

02-02–1
1890-1U-06H(02-02).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING DIAGRAM
id020200800100
With Advanced Keyless System

WHEEL UNIT

NO.1 NO.2 NO.3 NO.4

KEYLESS RF SIGNAL
RECEIVER INSTRUMENT
CLUSTER
PCM
ANTENNA
KEYLESS CM CAN_H
1X

CAN_L
1W
A 3A 3Q 1N

C 3C
CAN
DRIVER
E 2B
1B
DLC-2

ac9uuw00002455

With Keyless Entry System

WHEEL UNIT

NO.1 NO.2 NO.3 NO.4

RF SIGNAL
KEYLESS
RECEIVER INSTRUMENT
CLUSTER
PCM
ANTENNA
CAN_H
A 1X

CAN_L
1W
B
CAN
D 1N DRIVER
1B
DLC-2

ac9uuw00000770

End Of Sie

02-02–2
1890-1U-06H(02-02).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
TIRE PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD DIAGNOSIS
id020200800200
On-Board Diagnostic (OBD) Test Description
• The OBD test inspects the integrity and function of the TPMS and outputs the results when requested by the
specific tests.
• On-board diagnostic test also:
— Provides a quick inspection of the TPMS usually performed at the start of each diagnostic procedure.
— Provides verification after repairs to ensure that no other faults occurred during service.
• The OBD test is divided into 3 tests:
— Read/clear diagnostic results, PID monitor and active command mode.
02-02
Read/clear diagnostic results
• This function allows you to read or clear DTCs in the instrument cluster memory.

PID/Data monitor and record

• This function allows you to access certain data values, input signals, calculated values, and system status
information.

Active command modes

• This function allows you to control devices through the M-MDS.

Reading DTCs Procedure

1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “IC”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “IC”.
3. Select “Self Test”.
ac9uuw00000862
3. Verify the DTC according to the directions on the
screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
4. After completion of repairs, clear all DCTs stored in the instrument cluster. (See 09-02J-2 DTC TABLE
[INSTRUMENT CLUSTER].)

Clearing DTCs Procedures

1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “IC”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “IC”.
3. Select “Self Test”.
ac9uuw00000862
3. Verify the DTC according to the directions on the
screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.

02-02–3
1890-1U-06H(02-02).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
PID/Data Monitor and Record Procedure
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “IC”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “IC”.
3. Select “DataLogger”.
ac9uuw00000862
3. Select the applicable PID from the PID table.
4. Verify the PID data according to the directions on
the screen.

Note
• The PID/Data monitor function is used for monitoring the calculated value. Therefore, if the monitored
value of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually using a active command modes function.

Active Command Modes Procedure

1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “IC”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “IC”.
3. Select “DataLogger”.
ac9uuw00000862
3. Select the active command modes from the PID
table.
4. Perform the active command modes, inspect the operations for each parts.
• If there is no operation sound from the relay, motor, and solenoid after the active command mode
inspection is performed, it is possible that there is an open or short circuit in the wiring harness, relay, motor
or solenoid, or sticking and operation malfunction.

Freeze Frame PID Data Access Procedure

1. After the vehicle is identified, select the following items from the initialization screen of the M-MDS.
• This function is available for only the IDS (laptop PC)
1. Select the “Body” tab.
2. Select “TPMS Functions”.
3. Select “Freeze Frame Data”.

02-02–4
1890-1U-06H(02-02).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
DTC Table
DTC
Description Page
M-MDS
B1342 Instrument cluster internal malfunction (See 09-02J-8 DTC B1342 [INSTRUMENT
CLUSTER].)
B2143 ID registration failure (See 02-02-7 DTC B2143.)
B2477 Instrument cluster configuration not performed (See 09-02J-8 DTC B2477 [INSTRUMENT
CLUSTER].)
B2868 Wheel unit No.1 internal malfunction (See 02-02-8 DTC B2868, B2869, B2870,
B2871.) 02-02
B2869 Wheel unit No.2 internal malfunction (See 02-02-8 DTC B2868, B2869, B2870,
B2871.)
B2870 Wheel unit No.3 internal malfunction (See 02-02-8 DTC B2868, B2869, B2870,
B2871.)
B2871 Wheel unit No.4 internal malfunction (See 02-02-8 DTC B2868, B2869, B2870,
B2871.)
U0127 Communication failure between instrument (See 02-02-9 DTC U0127.)
cluster and keyless receiver
U2616 Wheel unit No.1 (No response) (See 02-02-11 DTC U2616, U2617, U2618,
U2619.)
U2617 Wheel unit No.2 (No response) (See 02-02-11 DTC U2616, U2617, U2618,
U2619.)
U2618 Wheel unit No.3 (No response) (See 02-02-11 DTC U2616, U2617, U2618,
U2619.)
U2619 Wheel unit No.4 (No response) (See 02-02-11 DTC U2616, U2617, U2618,
U2619.)

PID/DATA Monitor Table

PID Name Unit/
Condition/Specification Action
(Definition) Condition
AI_WU1_ID
AI_WU2_ID
• Replace the wheel unit.
AI_WU3_ID Indicates the wheel unit ID code.
– • Perform the wheel unit ID
AI_WU4_ID (During wheel unit ID registration.)
registration.
(Wheel unit ID code (during ID
registration))
AI_WU1_P
AI_WU2_P • Adjust tire pressure.
AI_WU3_P Indicates the tire pressure. (During ID • Replace the wheel unit.
Pa, psi
AI_WU4_P registration.) • Perform the wheel unit ID
(Tire pressure value (during ID registration.
registration))
FFD1_WU1_P
FFD1_WU2_P
FFD1_WU3_P Indicates the tire pressure. (Freeze
Pa, psi Adjust tire pressure.
FFD1_WU4_P frame PID data 1)
(Tire pressure value (freeze frame
PID data 1))
FFD2_WU1_P
FFD2_WU2_P
FFD2_WU3_P Indicates the tire pressure. (Freeze
Pa, psi Adjust tire pressure.
FFD2_WU4_P frame PID data 2)
(Tire pressure value (freeze frame
PID data 2))
FFD1_WU1_T
FFD1_WU2_T
FFD1_WU3_T Indicates the internal tire air
°C, °F Adjust tire pressure.
FFD1_WU4_T temperature. (Freeze frame PID data 1)
(Internal tire air temperature value
(freeze frame PID data 1))

02-02–5
1890-1U-06H(02-02).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
PID Name Unit/
Condition/Specification Action
(Definition) Condition
FFD2_WU1_T
FFD2_WU2_T
FFD2_WU3_T Indicates the internal tire air
°C, °F Adjust tire pressure.
FFD2_WU4_T temperature. (Freeze frame PID data 2)
(Internal tire air temperature value
(freeze frame PID data 2))
FFD1_MLG
Indicates the mileage. (Freeze frame
(Wheel unit mileage value (freeze m, mi (ft) Adjust tire pressure.
PID data 1)
frame PID data 1))
FFD2_MLG
Indicates the mileage. (Freeze frame
(Wheel unit mileage value (freeze m, mi (ft) Adjust tire pressure.
PID data 2)
frame PID data 2))
FFD1_SPD
Indicates the speed. (Freeze frame PID
(Wheel unit speed value (freeze KPH, MPH Adjust tire pressure.
data 1)
frame PID data 1))
FFD2_SPD
Indicates the speed. (Freeze frame PID
(Wheel unit speed value (freeze KPH, MPH Adjust tire pressure.
data 2)
frame PID data 2))
IC_DTC_CNT
– Indicates number of DTC Perform the DTC inspection.
(Number of continuous DTCs)
ID_LAST*
Indicates the last ID that is transmitted • Replace the wheel unit.
(Last received tire transmitter ID –
from the wheel unit. • Perform the configuration.
code value)
ID_WU1*
ID_WU2* • Replace the wheel unit.
Indicates the registered ID that is
ID_WU3* – • Perform the wheel unit ID
transmitted from the wheel unit.
ID_WU4* registration.
(Registered wheel unit ID code)
WU1_P*
WU2_P*
Indicates the tire pressure. (See 02-50- • Adjust tire pressure.
WU3_P* Pa, psi
1 SUSPENSION TECHNICAL DATA.) • Replace the wheel unit.
WU4_P*
(Tire pressure value)
WU1_T*
WU2_T*
Indicates the internal tire air
WU3_T* °C, °F Replace the wheel unit.
temperature.
WU4_T*
(Internal tire air temperature value)
* : Data transmission from the wheel unit occurs when the vehicle speed is 25 km/h {15.5 mph} or more. Due to
this, the current air pressure and temperature data can only be displayed after the vehicle is driven at 25 km/h
{15.5 mph} or more. Also, the ID_LAST, and tire pressure and internal tire air temperature data are erased
when the instrument cluster connector and the battery terminal are disconnected. If the instrument cluster is
replaced or the battery terminals are disconnected, drive the vehicle at 25 km/h {15.5 mph} or more and
display the tire pressure PID after the data transmission.
Active Command Modes Table
Command Name Definition Operation Note
IDR_MODE Wheel unit ID registration mode OFF/ON Ignition switch at ON

End Of Sie
MALFUNCTIONING WHEEL UNIT IDENTIFICATION
id020200800300

Note
• The tire pressure monitoring system (TPMS) does not identify the location of the malfunctioning wheel
unit on the vehicle (RF, LF, LR, RR). The TPMS identifies each wheel unit as No.1, No.2, No.3 and No.4. In
order to identify the location of the wheel unit, perform the following procedure.
1. Adjust the air pressure as follows:
— RF: 220 kPa {2.2 kgf/cm2, 32 psi}
— LF: 240 kPa {2.4 kgf/cm2, 35 psi}
— LR: 260 kPa {2.6 kgf/cm2, 38 psi}
— RR: 280 kPa {2.8 kgf/cm2, 40 psi}

02-02–6
1890-1U-06H(02-02).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
2. Turn the ignition switch off.
3. Connect the M-MDS to the DLC-2.
4. Turn the ignition switch to the ON position.
5. Drive the vehicle at a speed of 25 km/h {15.5 mph} or more for 2 min or more.
6. Select the following PIDs using the M-MDS, and monitor them.
— WU1_P
— WU2_P
— WU3_P
— WU4_P
7. Determine which wheel unit identification code
matches which wheel and tire by comparing the AIR PRESSURE
PID MONITOR VALUE
02-02
PID monitor values with the air pressure values VALUE SET IN STEP.1
set in Step 1. RF 220 KPA WU1_P 240 KPA
8. Select the ID_LAST PID using the M-MDS, and LF 240 KPA WU2_P 220 KPA
take a note of four displayed identification codes. LR 260 KPA
9. Inspect the DTCs using the M-MDS. WU3_P 280 KPA
End Of Sie RR 280 KPA WU4_P 260 KPA

FR: WU2_P
FL: WU1_P
RL: WU4_P
RR: WU3_P
acxuuw00001191

DTC B2143
id020200800400

DTC B2143 • ID registration failure

DETECTION
• Two or more codes are overlapping.
CONDITION
POSSIBLE
• ID registration procedure has not been performed properly.
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY THE PROGRAMMED ID Yes Register the wheel unit ID, then go to the next step.
• Turn the ignition switch off. (See 02-12-4 WHEEL UNIT ID REGISTRATION.)
• Connect the M-MDS to the DLC-2. No Go to the next step.
• Select the following PIDs using the M-MDS:
— ID_WU1
— ID_WU2
— ID_WU3
— ID_WU4
• Turn the ignition switch to the ON position.
• Is the same code in the output ID?
2 VERIFY TROUBLESHOOTING COMPLETED Yes • Repeat the inspection from Step 1.
• Clear the DTC from the memory. If the malfunction recurs, replace the instrument cluster
(See 02-02-3 TIRE PRESSURE and/or wheel unit.
MONITORING SYSTEM (TPMS) ON- (See 09-22-3 INSTRUMENT CLUSTER REMOVAL/
BOARD DIAGNOSIS.) INSTALLATION.)
• Drive the vehicle at a speed of 25 km/h {15.5 (See 02-12-5 WHEEL UNIT REMOVAL/
mph} or more for 10 min or more. INSTALLATION.)
• Is the same DTC present? No Go to the next step.
3 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. (See 02-02-3 TIRE
• Are there any other DTCs present? PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD
DIAGNOSIS.)
No DTC troubleshooting completed.

End Of Sie

02-02–7
1890-1U-06H(02-02).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
DTC B2868, B2869, B2870, B2871
id020200800500

B2868 Wheel unit No.1 (internal malfunction)

B2869 Wheel unit No.2 (internal malfunction)
DTC
B2870 Wheel unit No.3 (internal malfunction)
B2871 Wheel unit No.4 (internal malfunction)
DETECTION
• The instrument cluster receives error signals from the wheel unit.
CONDITION
POSSIBLE
• Internal malfunction of wheel unit
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 IDENTIFY MALFUNCTIONING WHEEL UNIT • Identify the malfunctioning wheel unit.
• (See 02-02-6 MALFUNCTIONING WHEEL UNIT • Replace and register the wheel unit. (See 02-12-4
IDENTIFICATION.) WHEEL UNIT ID REGISTRATION.)
• Go to the next step.
2 VERIFY TROUBLESHOOTING COMPLETED Yes Go to Step 1.
• Clear the DTC from the memory. No Go to the next step.
(See 02-02-3 TIRE PRESSURE
MONITORING SYSTEM (TPMS) ON-
BOARD DIAGNOSIS.)
• Drive the vehicle at a speed of 25 km/h {15.5
mph} or more for 10 min or more.
• Is the same DTC present?
3 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. (See 02-02-3 TIRE
• Are there any other DTCs present? PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD
DIAGNOSIS.)
No DTC troubleshooting completed.

End Of Sie

02-02–8
1890-1U-06H(02-02).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
DTC U0127
id020200800600

DTC U0127 • Communication failure between instrument cluster and keyless receiver
DETECTION
• The instrument cluster cannot receive signal from the keyless CM or keyless receiver.
CONDITION
With advanced keyless system
• Open or short circuit in the wiring harness between the keyless CM terminal 3Q and the instrument
cluster terminal 1N.
• Keyless control module malfunction.
• Instrument cluster malfunction.
POSSIBLE • Poor connection at connectors (female terminal) 02-02
CAUSE With keyless entry system
• Open or short circuit in the wiring harness between the keyless receiver terminal D and the instrument
cluster terminal 1N.
• Keyless receiver malfunction.
• Instrument cluster malfunction.
• Poor connection at connectors (female terminal)

With Advanced Keyless System

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT WHEEL UNIT SIGNAL FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the wiring harness for an open circuit
• Turn the ignition switch off. between keyless CM terminal 3Q and instrument cluster
• Disconnect keyless CM and instrument terminal 1N, then go to Step 5.
cluster connectors.
• Inspect for continuity between keyless CM
terminal 3Q (harness-side) and instrument
cluster terminal 1N (harness-side).
• Is there continuity?
2 INSPECT WHEEL UNIT SIGNAL FOR SHORT Yes Repair or replace the wiring harness for a short to power
TO POWER between keyless CM terminal 3Q and instrument cluster
• Turn the ignition switch off. terminal 1N, then go to Step 5.
• Disconnect keyless CM and instrument No Go to the next step.
cluster connectors.
• Measure the voltage between keyless CM
terminal 3Q (harness-side) and ground.
• Is there B+?
3 INSPECT WHEEL UNIT SIGNAL FOR SHORT Yes Repair or replace the wiring harness for a short to ground
TO GROUND between keyless CM terminal 3Q and instrument cluster
• Turn the ignition switch off. terminal 1N, then go to the next step.
• Disconnect keyless CM and instrument No Go to the next step.
cluster connectors.
• Inspect for continuity between keyless CM
terminal 3Q (harness-side) and ground.
• Is there continuity?
4 INSPECT FOR KEYLESS CM MALFUNCTION Yes Go to the applicable DTC inspection. (See 09-02D-3 DTC
• Turn the ignition switch off. TABLE [IMMOBILIZER SYSTEM (KEYLESS ENTRY
• Using the M-MDS, perform the DTC SYSTEM)].)
inspection for the keyless CM. No Go to the next step.
• Is any DTCs present?
5 VERIFY TROUBLESHOOTING COMPLETED Yes • If the malfunction recurs, replace the instrument cluster.
• Turn the ignition switch to the ON position (See 09-22-3 INSTRUMENT CLUSTER REMOVAL/
and drive the vehicle at a speed of 25 km/h INSTALLATION.)
{15.5 mph} or more. • Configure the instrument cluster. (See 09-22-4
• Clear the DTC from the memory. INSTRUMENT CLUSTER CONFIGURATION.)
(See 02-02-3 TIRE PRESSURE • Register the wheel unit ID. (See 02-12-4 WHEEL UNIT
MONITORING SYSTEM (TPMS) ON- ID REGISTRATION.)
BOARD DIAGNOSIS.) • Go to the next step.
• Is the same DTC present? No Go to the next step.
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. (See 02-02-3 TIRE
• Drive the vehicle at a speed of 25 km/h {15.5 PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD
mph} or more for 10 min or more. DIAGNOSIS.)
• Are there any other DTCs present? No DTC troubleshooting completed.

02-02–9
1890-1U-06H(02-02).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
With Keyless Entry System
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT WHEEL UNIT SIGNAL FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the wiring harness for an open circuit
• Turn the ignition switch off. between keyless receiver terminal D and instrument cluster
• Disconnect keyless receiver and instrument terminal 1N, then go to Step 4.
cluster connectors.
• Inspect for continuity between keyless
receiver terminal D (harness-side) and
instrument cluster terminal 1N (harness-
side).
• Is there continuity?
2 INSPECT WHEEL UNIT SIGNAL FOR SHORT Yes Repair or replace the wiring harness for a short to power
TO POWER between keyless receiver terminal D and instrument cluster
• Turn the ignition switch off. terminal 1N, then go to Step 4.
• Disconnect keyless receiver and instrument No Go to the next step.
cluster connectors.
• Measure the voltage between keyless
receiver terminal D (harness-side) and
ground.
• Is there B+?
3 INSPECT WHEEL UNIT SIGNAL FOR SHORT Yes Repair or replace the wiring harness for a short to ground
TO GROUND between keyless receiver terminal D and instrument cluster
• Turn the ignition switch off. terminal 1N, then go to the next step.
• Disconnect keyless receiver and instrument No Replace keyless receiver, then go to the next step. (See 09-
cluster connectors. 14-58 KEYLESS RECEIVER REMOVAL/INSTALLATION.)
• Inspect for continuity between keyless
receiver terminal D (harness-side) and
ground.
• Is there continuity?
4 VERIFY TROUBLESHOOTING COMPLETED Yes • If the malfunction recurs, replace the instrument cluster.
• Clear the DTC from the memory. (See 09-22-3 INSTRUMENT CLUSTER REMOVAL/
(See 02-02-3 TIRE PRESSURE INSTALLATION.)
MONITORING SYSTEM (TPMS) ON- • Configure the instrument cluster. (See 09-22-4
BOARD DIAGNOSIS.) INSTRUMENT CLUSTER CONFIGURATION.)
• Turn the ignition switch to the ON position • Register the wheel unit ID. (See 02-12-4 WHEEL UNIT
and wait for 30 s. ID REGISTRATION.)
• Is the same DTC present? • Go to the next step.
No Go to the next step.
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. (See 02-02-3 TIRE
• Drive the vehicle at a speed of 25 km/h {15.5 PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD
mph} or more for 10 min or more. DIAGNOSIS.)
• Are there any other DTCs present? No DTC troubleshooting completed.

End Of Sie

02-02–10
1890-1U-06H(02-02).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時１分

ON-BOARD DIAGNOSTIC
DTC U2616, U2617, U2618, U2619
id020200800700

U2616 Wheel unit No.1 (No response)

U2617 Wheel unit No.2 (No response)
DTC
U2618 Wheel unit No.3 (No response)
U2619 Wheel unit No.4 (No response)
DETECTION
• The keyless receiver has continuously not received a signal from the wheel unit for a certain period.
CONDITION
• Wheel unit identification code is not registered in the instrument cluster.
POSSIBLE • No signal is received from the wheel unit.
CAUSE • Wheel unit is not installed. 02-02
• Poor connection at connectors (female terminal).

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY WHEEL UNIT IS INSTALLED TO Yes Go to the Step 3.
EACH WHEEL No • Install the wheel unit. (See 02-12-5 WHEEL UNIT
• Are all four wheels equipped with a wheel REMOVAL/INSTALLATION.)
unit? • Register the wheel unit ID. (See 02-12-4 WHEEL UNIT
ID REGISTRATION.)
• Go to the next step.
2 INSPECT FOR DTCs Yes Go to the next step.
• Drive the vehicle at a speed of 25 km/h {15.5 No With advanced keyless system: go to the Step 4.
mph} or more for 10 min or more. With keyless entry system: go to the Step 5.
• Is the same DTC present?
3 IDENTIFY MALFUNCTIONING WHEEL UNIT • Identify the malfunctioning wheel unit.
• (See 02-02-6 MALFUNCTIONING WHEEL UNIT • Replace the wheel unit. (See 02-12-5 WHEEL UNIT
IDENTIFICATION.) REMOVAL/INSTALLATION.)
• Register the wheel unit ID. (See 02-12-4 WHEEL UNIT
ID REGISTRATION.)
• Go to the Step 5.
4 INSPECT FOR KEYLESS CM MALFUNCTION Yes Go to the applicable DTC inspection. (See 09-02D-3 DTC
• Turn the ignition switch off. TABLE [IMMOBILIZER SYSTEM (KEYLESS ENTRY
• Using the M-MDS, perform the DTC SYSTEM)].)
inspection for the keyless CM. No Go to the next step.
• Is any DTCs present?
5 VERIFY TROUBLESHOOTING COMPLETED Yes • If the malfunction recurs, replace the instrument cluster.
• Clear the DTC from the memory. (See 09-22-3 INSTRUMENT CLUSTER REMOVAL/
(See 02-02-3 TIRE PRESSURE INSTALLATION.)
MONITORING SYSTEM (TPMS) ON- • Configure the instrument cluster. (See 09-22-4
BOARD DIAGNOSIS.) INSTRUMENT CLUSTER CONFIGURATION.)
• Drive the vehicle at a speed of 25 km/h {15.5 • Register the wheel unit ID. (See 02-12-4 WHEEL UNIT
mph} or more for 10 min or more. ID REGISTRATION.)
• Is the same DTC present? • Go to the next step.
No Go to the next step.
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. (See 02-02-3 TIRE
• Are there any other DTCs present? PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD
DIAGNOSIS.)
No DTC troubleshooting completed.

Note
• If the installed wheel unit ID number is known, verification of whether the instrument cluster is receiving
data from the wheel unit can be easily confirmed using the following procedure:
1. Drive the vehicle at 25 km/h {15.5 mph} or more, and send data from the wheel unit.
2. Select [ID_LAST] from the PID items, and monitor the data.
3. Verification that the instrument cluster is receiving data is possible if the monitored ID number
matches the installed wheel unit ID number.
• If the wheel unit has been newly replaced, the TPMS warning light may flashes before the ID registration
is complete, and DTC U2616, U2617, U2618 and U2619 may be stored in the memory. In this case, re-
implement the wheel unit ID registration, and after confirming that the TPMS warning light is no longer
flashing, erase the DTC. If the TPMS warning light does not go out, a malfunction on any one of the wheel
units may have occurred and the ID registration will not have been correctly performed. Repeat the
diagnostic procedure from Step 1 and perform and inspection.

End Of Sie

02-02–11
1890-1U-06H(02-03).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時３分

SYMPTOM TROUBLESHOOTING
02-03 SYMPTOM TROUBLESHOOTING
TIRE PRESSURE MONITORING No.1 TPMS WARNING LIGHT
SYSTEM (TPMS) ILLUMINATES CONTINUOUSLY . . . . . . 02-03–4
WIRING DIAGRAM . . . . . . . . . . . . . . . . 02-03–2 No.2 TPMS WARNING LIGHT
FOREWORD . . . . . . . . . . . . . . . . . . . . . . 02-03–2 (LOW PRESSURE WARNING)
PRECAUTION . . . . . . . . . . . . . . . . . . . . . 02-03–3 ILLUMINATES AFTER ENGINE
Intermittent Concern START AND TURNS OFF AFTER
Troubleshooting . . . . . . . . . . . . . . . . . 02-03–3 DRIVING FOR PERIOD OF TIME . . . . . 02-03–5
SYMPTOM No.3 WHEEL UNIT ID REGISTRATION 02-03
TROUBLESHOOTING. . . . . . . . . . . . . . 02-03–4 CANNOT BE PERFORMED (TPMS
WARNING LIGHT FLASHES) . . . . . . . . 02-03–6
Display Of M-MDS (Example) . . . . . . . . 02-03–7

End of Toc
WM: TIRE PRESSURE MONITORING SYSTEM

02-03–1
1890-1U-06H(02-03).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時３分

SYMPTOM TROUBLESHOOTING
TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING DIAGRAM
id020300800100
With advanced keyless system
WHEEL UNIT

NO.1 NO.2 NO.3 NO.4

KEYLESS RF SIGNAL
RECEIVER INSTRUMENT
CLUSTER
PCM
ANTENNA
KEYLESS CM CAN_H
1X

CAN_L
1W
A 3A 3Q 1N

C 3C
CAN
DRIVER
E 2B
1B
DLC-2

ac9uuw00002455

With keyless entry system

WHEEL UNIT

NO.1 NO.2 NO.3 NO.4

RF SIGNAL
KEYLESS
RECEIVER INSTRUMENT
CLUSTER
PCM
ANTENNA
CAN_H
A 1X

CAN_L
1W
B
CAN
D 1N DRIVER
1B
DLC-2

ac9uuw00000770

End Of Sie
FOREWORD
id020300800200
• Before performing the steps in Symptom Troubleshooting, perform the On-board Diagnostic Inspection. To
check the DTC, follow the DTC Inspection steps. (See 02-02-3 TIRE PRESSURE MONITORING SYSTEM
(TPMS) ON-BOARD DIAGNOSIS.)
End Of Sie

02-03–2
1890-1U-06H(02-03).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時３分

SYMPTOM TROUBLESHOOTING
PRECAUTION
id020300800300
Intermittent Concern Troubleshooting
Vibration method
• If malfunction occurs or becomes worse while driving on a rough road or when the engine is vibrating, perform
the steps below.

Note
• There are several reasons why vehicle or engine vibration could cause an electrical malfunction. Some of
the things to check for are:
— Connectors not fully seated. 02-03
— Wire harnesses not having full play.
— Wires laying across brackets or moving parts.
— Wires routed too close to hot parts.
• An improperly routed, improperly clamped, or loose harness can cause wiring to become pinched
between parts.
• The connector joints, points of vibration, and places where wire harnesses pass through the firewall, body
panels and other panels are the major areas to be checked.

Inspection method for switch and/or sensor connectors or wires

1. Connect M-MDS to DLC-2.
2. Turn the ignition switch to the ON position (engine off).

Note
• If engine starts and runs, perform the following steps at idle.

3. Access PIDs for the switch you are inspecting.

4. Turn switch on manually.
5. Shake each connector or wire harness a bit
vertically and horizontally while monitoring the
PID.
• If PID value is unstable, check for poor
connection.

ac9uuw00002493

Inspection method for sensors

1. Connect M-MDS to DLC-2.
2. Turn the ignition switch to the ON position (engine off).

Note
• If engine starts and runs, perform the following steps at idle.

3. Access PIDs for the switch you are inspecting.

4. Vibrate the sensor slightly with your finger.
• If PID value is unstable or malfunction occurs, check for poor connection and/or poorly mounted sensor.

02-03–3
1890-1U-06H(02-03).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時３分

SYMPTOM TROUBLESHOOTING
Connector terminal check method
1. Check the connection condition of each female terminal.
2. Insert male terminal; fit the female terminal side
to female terminal and check to see whether the
malfunction is in the female terminal or not.
End Of Sie

acxuuw00000962

SYMPTOM TROUBLESHOOTING
id020300800400

No. Symptom
1 TPMS warning light illuminates continuously.
TPMS warning light (low pressure warning) illuminates after engine start and turns off after driving for a period
2
of time.
3 Wheel unit ID registration cannot be performed (TPMS warning light flashes).

End Of Sie
No.1 TPMS WARNING LIGHT ILLUMINATES CONTINUOUSLY
id020300800500

Caution
• The tire pressure cannot be measured accurately after driving for a long period due to the internal
temperature and pressure. Stop the vehicle for approx. 1 hour and then perform the tire pressure
measurement and adjustment.
• Use a high accuracy digital gauge for measurement of the tire pressure.

Note
• If the DTC clearing procedure is implement, the TPMS warning light turns off.

1 TPMS warning light illuminates continuously

[TROUBLESHOOTING HINTS]
• Tire pressure is lower than the specification.(such as loss of air pressure due to puncture.)

STEP INSPECTION ACTION

1 INSPECT THE TIRE Yes Remove any foreign object. Replace the tire if necessary,
• Is there any foreign object adhering to the and then go to the next step.
tire? No Go to the next step.
2 INSPECT THE TIRE PRESSURE Yes Adjust the tire pressure to the specification when the tires
• Is the tire pressure lower than the are cold, and then go tot the next step.
specification? No Go to the next step.
3 DOES THE TPMS WARNING LIGHT TURN Yes Troubleshooting completed. Explain to the customer what
OFF? has been repaired.
No Go to the next step.
4 DRIVE THE VEHICLE AT 25 KM/H FOR 10 Yes Troubleshooting completed. Explain to the customer what
MIN. has been repaired.
• Does the TPMS warning light turn off? No Adjust the tire pressure to the specification while tires are
cold, and then return to Step 1.

Note
• If the TPMS warning light does not turn off after
repeating this step, the tire may be flat.

End Of Sie

02-03–4
1890-1U-06H(02-03).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時３分

SYMPTOM TROUBLESHOOTING
No.2 TPMS WARNING LIGHT (LOW PRESSURE WARNING) ILLUMINATES AFTER ENGINE START AND
TURNS OFF AFTER DRIVING FOR PERIOD OF TIME
id020300800600

Caution
• The tire pressure cannot be measured accurately after driving for a long period due to increased
internal temperature and pressure. Stop the vehicle for approx. 1 hour and then perform the tire
pressure measurement and adjustment.
• Use a high accuracy digital gauge for measurement of the tire pressure.

Note
02-03
• The tire pressure normally decreases by approx. 7 kPa {0.07 kgf/cm2, 1.02 psi} per month even if the
tire is normal.
• The FFD (temperature and pressure) stored when the TPMS warning light is turned on and off can be
verified by operating the M-MDS.

TPMS warning light (low pressure warning) illuminates after engine start and turns off after driving
2
for a period of time.
[TROUBLESHOOTING HINTS]
• The tire pressure decreases (approaches value to illuminate TPMS warning light) when the internal temperature of the tire
is low.

STEP INSPECTION ACTION

1 INSPECT THE TIRE Yes Remove any foreign object. Replace the tire if necessary,
• Is there any foreign object adhering to the and then go to the next step.
tire? No Go to the next step.
2 MEASURE THE TIRE PRESSURE WHEN THE Yes Adjust the tire pressure to the specification while the tires
TIRES ARE COLD are cold, and then go to the next step.
• Has the tire pressure decreased No Go to the next step.
(approaches value to illuminate TPMS
warning light)?
3 IS THE MALFUNCTION CORRECTED? Yes Troubleshooting completed.
No Verify troubleshooting again and return to Step 1 if the
malfunction recurs.

End Of Sie

02-03–5
1890-1U-06H(02-03).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時３分

SYMPTOM TROUBLESHOOTING
No.3 WHEEL UNIT ID REGISTRATION CANNOT BE PERFORMED (TPMS WARNING LIGHT FLASHES)
id020300800900

Caution
• Activate the wheel unit ID registration mode using the M-MDS, and perform the following steps if
the TPMS warning light does not turn off after driving at 25 km/h {15.5 mph} or more for 10 min or
more.

3 Wheel unit ID registration cannot be performed (TPMS warning light flashes).

[TROUBLESHOOTING HINTS]
• New wheel unit malfunction (caused when installing to wheel)
• Any malfunction on an old wheel unit which has not been replaced.

STEP INSPECTION ACTION

1 CAN THE WHEEL UNIT ID REGISTERED? Yes Trouble shooting completed. (Adjust the tire pressure on
• Connect the M-MDS. four wheels, and then return the vehicle to the customer.)
• Display the wheel unit ID registration No Go to the next step.
condition (ID and tire pressure table) using
the M-MDS.
• Temporarily remove the battery and reinstall
it immediately.

Note
• If the battery is removed, the tire
pressure data for WU_1 to WU_4
stored in the instrument cluster is
reset.
• Pressure is 0 kPa {0 kgf/cm2, 0 psi}
when it is displayed again using the M-
MDS.

• Set tire pressure for the four wheels

separately.
• Perform the wheel unit ID registration again.
• Can the ID be registered?
2 VERIFY THE WHEEL UNIT ID REGISTRATION Yes Replace with a new wheel unit, and then go to Step 4.
CONDITIONS (ID AND TIRE PRESSURE No Go to the next step.
TABLE) USING THE M-MDS
• Refer to [M-MDS display (example)] to
specify wheel unit for which the ID could not
be registered. (See 02-03-7 Display Of M-
MDS (Example).)
• Is the wheel unit for which the ID could not
be registered a new wheel unit?
Caution
• ID numbers of WU_1 to WU_4 are
updated when wheel on all of four
wheels are registered.
3 Replace the old wheel unit, and then go tot the next step (any malfunction on an old wheel unit which has not been
replaced).
4 CAN THE WHEEL UNIT ID REGISTERED? Yes Troubleshooting completed.
• Perform the wheel unit ID registration using No Verify troubleshooting again and return to Step 1 if the
the M-MDS. malfunction recurs.

02-03–6
1890-1U-06H(02-03).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時３分

SYMPTOM TROUBLESHOOTING
Display Of M-MDS (Example)
Registered ID: 0xAAAAAAAA, 0xBBBBBBBB, 0xCCCCCCCC, and 0xDDDDDDDD (AAAAAAAA, BBBBBBBB,
CCCCCCCC, and DDDDDDDD mean arbitrary numbers.)
Unregistered ID: 0x00000000
Tire pressure: aaa kPa, bbb kPa, ccc kPa, ddd kPa (aaa, bbb, ccc, and ddd mean measurement value.)
* The battery is removed, the stored tire pressure is reset to 0 kPa.

Three registered wheel units and a replaced wheel unit

When a replaced wheel unit malfunctions
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD 02-03
ID Number (Candidate) 0x00000000 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa bbb kPa ccc kPa 0 kPa
Tire Pressure (Candidate) 0 kPa 0 kPa 0 kPa 0 kPa

When a registered wheel unit malfunctions

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa bbb kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa

When two registered wheel unit malfunction

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa

When a replaced wheel unit and a registered wheel unit malfunction

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0x00000000 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa bbb kPa 0 kPa 0 kPa
Tire Pressure (Candidate) 0 kPa 0 kPa 0 kPa 0 kPa

When a replaced wheel unit and two registered wheel units malfunctions
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0x00000000 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) 0 kPa 0 kPa 0 kPa 0 kPa

When three registered wheel units malfunction

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa

Two registered wheel units and two replaced wheel units

When a replaced wheel unit malfunctions
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa bbb kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa

02-03–7
1890-1U-06H(02-03).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時３分

SYMPTOM TROUBLESHOOTING
When a registered wheel unit malfunctions
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0xFFFFFFFF 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa fff kPa 0 kPa 0 kPa

When two replaced wheel units malfunction

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0x00000000 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa bbb kPa 0 kPa 0 kPa
Tire Pressure (Candidate) 0 kPa 0 kPa 0 kPa 0 kPa

When two registered wheel units malfunction

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0xFFFFFFFF 0x00000000 0x00000000
Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa fff kPa 0 kPa 0 kPa

When a replaced wheel unit and a registered wheel unit malfunction

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa

When two replaced wheel units and a registered wheel unit malfunction
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0x00000000 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) 0 kPa 0 kPa 0 kPa 0 kPa

When a replaced wheel unit and two registered wheel units malfunction
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa

A registered wheel unit and three replaced wheel units

When a registered wheel unit malfunctions
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0xFFFFFFFF 0xGGGGGGGG 0x00000000
Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa fff kPa ggg kPa 0 kPa

When a replaced wheel unit malfunctions

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0xFFFFFFFF 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa fff kPa 0 kPa 0 kPa

02-03–8
1890-1U-06H(02-03).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時３分

SYMPTOM TROUBLESHOOTING
When a replaced wheel unit and a registered wheel unit malfunction
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0xFFFFFFFF 0x00000000 0x00000000
Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa fff kPa 0 kPa 0 kPa

When two replaced wheel units malfunction

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD 02-03
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa

When two replaced wheel units and a registered wheel unit malfunction
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa

When three replaced wheel units malfunction

WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0x00000000 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) 0 kPa 0 kPa 0 kPa 0 kPa

End Of Sie

02-03–9
1890-1U-06H(02-10).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時４分

GENERAL PROCEDURES
02-10 GENERAL PROCEDURES
GENERAL PROCEDURES Suspension Links
(SUSPENSION) . . . . . . . . . . . . . . . . . . . 02-10–1 Removal/Installation . . . . . . . . . . . . . . 02-10–1
Wheels and Tires Steering Links
Removal/Installation. . . . . . . . . . . . . . 02-10–1 Removal/Installation . . . . . . . . . . . . . . 02-10–1
Connector Disconnection . . . . . . . . . . . 02-10–1

End of Toc
GENERAL PROCEDURES (SUSPENSION)
WM: SUSPENSION

02-10
id021000800300
Wheels and Tires Removal/Installation
1. When installing the wheels and tires, tighten the
wheel nuts in a criss-cross pattern to the following
tightening torque.

Tightening torque 1
• 107.8—147.0 N·m {11.0—14.9 kgf·m, 79.6— 4 3
108.4 ft·lbf}
2 5

acxuuw00001032

Suspension Links Removal/Installation

1. For the joint sections with rubber bushings, raise the vehicle using a lift, and then temporarily tighten the
installation bolts and nuts. Lower the vehicle to the ground and tighten them completely with the specified
torque.

Steering Links Removal/Installation

1. If any steering fluid line has been disconnected, perform the following after installation of the power steering
components.
— Power steering fluid amount inspection
— Power steering fluid leakage inspection
— Air bleeding

Power steering fluid

ATF M-III, M-V or equivalent (e.g. Dexron®II)

Connector Disconnection
1. Disconnect the negative battery cable before performing any work that requires handling of connectors.
End Of Sie

02-10–1
1890-1U-06H(02-11).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時５分

WHEEL ALIGNMENT
02-11 WHEEL ALIGNMENT
WHEEL ALIGNMENT REAR WHEEL ALIGNMENT
PRE-INSPECTION . . . . . . . . . . . . . . . . 02-11–1 [2WD] . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-11–4
FRONT WHEEL ALIGNMENT . . . . . . . . 02-11–2 Camber/Total Toe-in
Steering Angle Adjustment . . . . . . . . . 02-11–2 Adjustment . . . . . . . . . . . . . . . . . . . . . 02-11–4
Camber and Caster Adjustment. . . . . . 02-11–3 REAR WHEEL ALIGNMENT
Total Toe-in Adjustment . . . . . . . . . . . . 02-11–3 [AWD] . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-11–5
Camber/Total Toe-in
Adjustment . . . . . . . . . . . . . . . . . . . . . 02-11–5 02-11
End of Toc
WHEEL ALIGNMENT PRE-INSPECTION
WM: SUSPENSION

id021100800100
1. Park the vehicle on a level ground, in an unloaded condition*, and with the wheels straight forward.
*
: Unloaded condition.....Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack
and tools are in designated position.
2. Inspect the tire pressure.
• Adjust to the recommended pressure if necessary. (See 02-50-1 SUSPENSION TECHNICAL DATA.)
3. Inspect the wheel bearing play. (See 03-11-2 WHEEL HUB, STEERING KNUCKLE INSPECTION.) (See 03-
12-2 WHEEL HUB COMPONENT INSPECTION.)
• Correct if necessary.
4. Inspect the wheel runout. (See 02-50-1 SUSPENSION TECHNICAL DATA.)
• Correct if necessary.
5. Rock the vehicle, and verify that there is no looseness in the steering wheel joint and suspension ball joint.
6. Rock the vehicle, and verify that the shock absorber operates properly.
7. Measure height H from the center of the wheel to FENDER BRIM
the fender brim. SEC. A-A MEASUREMENT POINT
8. Verify that the difference between the left and
right dimension H is within the specification. A
• If it exceeds the specification, repeat the Step
2—7. A
H
Standard
10 mm {0.39 in} or less

End Of Sie
WM: FRONT SUSPENSION

am8rrw00001816

02-11–1
1890-1U-06H(02-11).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時５分

WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT
id021100800200

Front wheel alignment [2WD] (Unloaded)*1

Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 38°
[Tolerance ±3°] Outer 32°
[Tolerance ±4 {±0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°09′±0°18′
Caster angle*2 [Tolerance ±1°] 3°01′ 3°02′ 3°03′ 3°04′
Camber angle [Tolerance ±1°]
*2 −0°19′ −0°20′ −0°21′
Steering axis inclination (Reference value) 11°31′ 11°32′ 11°33′ 11°34′ 11°35′

*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.

Front wheel alignment [AWD] (Unloaded)*1

Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 38°
[Tolerance ±3°] Outer 32°
[Tolerance ±4 {±0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°09′±0°18′
Caster angle*2 [Tolerance ±1°] 3°02′ 3°03′ 3°04′ 3°05′
Camber angle [Tolerance ±1°]
*2 −0°19′ −0°20′ −0°21′
Steering axis inclination (Reference value) 11°31′ 11°32′ 11°33′ 11°34′ 11°35′

*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.

Steering Angle Adjustment

1. Jack up the front of the vehicle and support it on safety stands.
2. Loosen the locknut of the tie-rod end.
3. Remove the rack boot clamp.
4. Rotate the tie rod and adjust the steering angle.

Note
• The travel distance of the right and left tie rods should be the same.

5. Rotate the tie rod and adjust so that the length L

shown in the figure is within the specification.

Dimension L (reference value)

33.9—43.9 mm {1.34—1.72 in}

Difference between left and right

3 mm {0.12 in} or less

6. Tighten the locknut of the tie-rod end. L

Tightening torque
acxuuw00000348
68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2
ft·lbf}

7. Correct the rack boot twists.

8. Install and fix the rack boot clamp.
9. After adjusting the steering angle, always inspect and adjust the total toe-in.

02-11–2
1890-1U-06H(02-11).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時５分

WHEEL ALIGNMENT
Camber and Caster Adjustment
1. Remove the windshield wiper arm (LH). (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/
INSTALLATION.)
2. Partially peel back the cowl grille. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
3. Jack up the front of the vehicle and support it on safety stands.
4. Remove the mounting rubber nuts.

02-11

DIRECTION
INDICATOR

acxuuw00002203

5. Push the shock absorber and coil spring

VEHICLE OF FRONT
component downward, and turn the direction
indicator to the desired position. DIRECTION DIRECTION
INDICATOR INDICATOR

C C

A B B A

LEFT SIDE RIGHT SIDE

acxuuw00001947

Adjustment value from original position

Direction indicator position Camber angle Caster angle
A 0° −0°22′
B +0°22′ −0°22′
C +0°22′ 0°

6. Install the shock absorber and coil spring, then tighten the mounting rubber nuts to the specified torque.

Tightening torque
46.1—62.7 N·m {4.71—6.39 kgf·m, 34.1—46.2 ft·lbf}

7. Install the cowl grille. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)

8. Install the windshield wiper arm (LH). (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/
INSTALLATION.)

Total Toe-in Adjustment

1. Jack up the front of the vehicle and support it on safety stands.
2. Loosen the locknut of the tie-rod end.
3. Remove the rack boot clamp.
4. Adjust the total toe-in by rotating each tie rod (left and right) in the opposite directions by the same amount
respectively.

Note
• Toe angle changes by approx. 6 mm {0.2 in} per one rotation of the tie rod for one wheel.
• Each tie rod has a right-hand thread. When increasing the toe-in angle, rotate the right tie rod toward the
front of the vehicle and rotate the left tie rod toward the rear of the vehicle by the same amount.

5. Tighten the locknut of the tie-rod end.

Tightening torque
68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}

6. Verify that the rack boot does not have any twisting and install the rack boot clamp.
End Of Sie

02-11–3
1890-1U-06H(02-11).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時５分

WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT [2WD]
WM: REAR SUSPENSION

id0211008003a3

Rear wheel alignment [2WD] (Unloaded) *1

Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
[Tolerance ±4
(mm {in}) 2 {0.08}
Total toe-in [{±0.16}]
(degree) 0°09′±0°18′
*2
Camber angle (Reference value) -0°27′ -0°28′ -0°30′ -0°31′ -0°33′
[Tolerance ±1°]
Thrust angle (Reference value)
0°
[Tolerance ±0°48′]
*1
: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2
: Difference between left and right must not exceed 1°30′.

Camber/Total Toe-in Adjustment

1. Loosen the securing nut of the adjusting cam bolt.
2. Rotate the adjusting cam bolt in either direction to ADJUSTING CAM BOLT
adjust the camber and total toe-in.

REAR LOWER ARM

ADJUSTING CAM BOLT REAR LATERAL LINK

ac9uuw00001202

Camber
Rear lower arm side Rear lateral link side
Adjusting cam bolt rotation direction
Left wheel Right wheel Left wheel Right wheel
Clockwise direction Negative Positive Positive Negative
Counterclockwise direction Positive Negative Negative Positive

Total toe-in
Rear lower arm side Rear lateral link side
Adjusting cam bolt rotation direction
Left wheel Right wheel Left wheel Right wheel
Clockwise direction Toe-in Toe-out Toe-in Toe-out
Counterclockwise direction Toe-out Toe-in Toe-out Toe-in

3. Fix the adjusting cam bolt, and tighten the nut.

Tightening torque
• 120—163 N·m {12.3—16.6 kgf·m, 89—120 ft·lbf}

End Of Sie

02-11–4
1890-1U-06H(02-11).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時５分

WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT [AWD]
id0211008003a6

Rear wheel alignment [AWD] (Unloaded) *1

Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
[Tolerance ±4
(mm {in}) 2 {0.08}
Total toe-in [{±0.16}]
(degree) 0°09′±0°18′
*2
Camber angle (Reference value) -0°26′ -0°27′ -0°29′ -0°30′ -0°32′ 02-11
[Tolerance ±1°]
Thrust angle (Reference value)
0°
[Tolerance ±0°48′]
*1
: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2
: Difference between left and right must not exceed 1°30′.

Camber/Total Toe-in Adjustment

1. Loosen the securing nut of the adjusting cam bolt.
2. Rotate the adjusting cam bolt in either direction to ADJUSTING CAM BOLT
adjust the camber and total toe-in.

REAR LOWER ARM

ADJUSTING CAM BOLT REAR LATERAL LINK

ac9uuw00001203

Camber
Rear lower arm side Rear lateral link side
Adjusting cam bolt rotation direction
Left wheel Right wheel Left wheel Right wheel
Clockwise direction Negative Positive Positive Negative
Counterclockwise direction Positive Negative Negative Positive

Total toe-in
Rear lower arm side Rear lateral link side
Adjusting cam bolt rotation direction
Left wheel Right wheel Left wheel Right wheel
Clockwise direction Toe-in Toe-out Toe-in Toe-out
Counterclockwise direction Toe-out Toe-in Toe-out Toe-in

3. Fix the adjusting cam bolt, and tighten the nut.

Tightening torque
• 120—163 N·m {12.3—16.6 kgf·m, 89—120 ft·lbf}

End Of Sie

02-11–5
1890-1U-06H(02-12).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時６分

WHEEL AND TIRES

02-12 WHEEL AND TIRES
WHEEL AND TIRE TIRE PRESSURE ADJUSTMENT
SPECIFICATION . . . . . . . . . . . . . . . . . . 02-12–1 (WITH TPMS) . . . . . . . . . . . . . . . . . . . . . 02-12–3
WHEEL BALANCE ADJUSTMENT WHEEL UNIT ID
(ALUMINUM ALLOY WHEEL) . . . . . . . 02-12–2 REGISTRATION . . . . . . . . . . . . . . . . . . . 02-12–4
Adhesive-type Balance Weight Using M-MDS . . . . . . . . . . . . . . . . . . . . 02-12–4
(Outer) . . . . . . . . . . . . . . . . . . . . . . . . 02-12–2 Without Using M-MDS. . . . . . . . . . . . . . 02-12–4
Knock-type Balance Weight WHEEL UNIT
(Inner) . . . . . . . . . . . . . . . . . . . . . . . . 02-12–3 REMOVAL/INSTALLATION . . . . . . . . . . 02-12–5 02-12
Remaining Amount of Unbalance Valve Core Removal Note . . . . . . . . . . . 02-12–5
Confirmation. . . . . . . . . . . . . . . . . . . . 02-12–3 Wheel Unit Removal Note . . . . . . . . . . . 02-12–5
Wheel Unit Installation Note . . . . . . . . . 02-12–6

End of Toc
WHEEL AND TIRE SPECIFICATION
WM: WHEELS AND TIRES

id021200800100

Item Specification
Size P245/60R18 104H P245/50R20 102V
Air pressure Front
Tire 250 {36} 230 {34}
(kPa {psi}) Rear
Remaining treed (mm {in}) 1.6 {0.07}
Size 18×7 1/2J 20×7 1/2J
Material Aluminum alloy
Wheel Wheel offset (mm {in}) 45 {1.8}
Wheel pitch circle
(mm {in}) 114.3 {4.5}
diameter
Standard
tire Wheel and tire runout Lateral direction 2.0 {0.08}
(mm {in}) Radial direction 1.5 {0.06}
Adhesive-type*1: 10 {0.35} max. Adhesive-type*1: 6 {0.21} max.
Knock-type*2: 6 {0.21} max. Knock-type*2: 4 {0.14} max.
*1: Total weight exceeds 160 g {5.65 oz}.
Wheel and tire imbalance (g {oz}) *2
: One balance weight: 60 g {2.12 oz} max. If the total weight
exceeds 100 g {3.53 oz} on one side, rebalance after moving the
tire around on the rim. Do not use three or more balance
weights.
Wheel nut tightening torque (N·m {kgf·m, ft·bf}) 107.8—147.0 {11.0—14.9, 79.6—108.4}
Size T155/90D 18
Tire Air pressure (kPa {psi}) 420 {60}
Remaining treed (mm {in}) 1.6 {0.07}
Size 18×4T
Material Steel
Temporary
Wheel Wheel offset (mm {in}) 40 {1.57}
spare tire
Wheel pitch circle
(mm {in}) 114.3 {4.5}
diameter
Wheel and tire runout Lateral direction 2.0 {0.08}
(mm {in}) Radial direction 1.5 {0.06}
Wheel nut tightening torque (N·m {kgf·m, ft·bf}) 107.8—147.0 {11.0—14.9, 79.6—108.4}

End Of Sie

02-12–1
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WHEEL AND TIRES

WHEEL BALANCE ADJUSTMENT (ALUMINUM ALLOY WHEEL)
id021200801100

Caution
• Adjust the outer wheel balance first, then the inner wheel balance.
• Be careful not to scratch the wheels.

Adhesive-type Balance Weight (Outer)

1. Remove the old balance weight from the wheel.
2. Remove the double-sided adhesive tape remaining on the wheel, then clean and degrease the bonding area.
3. Set the wheel on a wheel balancer, measure the amount of unbalance and the position with the mode set for
knock-type balance weight.
4. Multiply the amount of unbalance by 1.6 to get the balance weight value.
5. Select a balance weight closest to the weight
ADHESIVE-TYPE
value and attach the balance weight on the BALANCE WEIGHT ATTACH ALONG GAP
position (outer) indicated by the wheel balancer. WHEEL

Example calculation of balance weight value TIRE

Indicated amount of unbalance: 23 g {0.81 CENTER OF
oz} BALANCE WEIGHT
23 g {0.81 oz}×1.6 = 36.8 g {1.30 oz}
Selected balance weight value: 35 g {1.24
oz} INNER OUTER POSITION INDICATED
BY WHEEL BALANCER
Note
• When selecting a balance weight, select one
am8rrw00001345

closest to the calculated value.

Example: 32.4 g {1.14 oz}= 30 g {1.06 oz}, 32.5 g {1.15 oz}= 35 g {1.24 oz}

Caution
• Use a genuine balance weight or equivalent (steel).
• When attaching the weight balance, press the balance weight with a force of 25 N {2.5 kgf, 5.5 lbf}
per 5 g {0.17 oz} for 2 seconds or more.

6. If attaching 2 balance weights, position them so

that each is on either side of the position indicated
by the wheel balancer. ATTACH ON EITHER SIDE

Caution
• Do not attach weight balances in a row.
• Do not overlap the balance weights.
• Total weight must not exceed 160g {5.65
oz}. POSITION INDICATED BY WHEEL BALANCER

NO GOOD NO GOOD
(DO NOT ATTACH (DO NOT OVERLAP)
IN A ROW)

am8rrw00001346

02-12–2
1890-1U-06H(02-12).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時６分

WHEEL AND TIRES

Knock-type Balance Weight (Inner)
1. Measure the amount of unbalance with a wheel balancer.
2. Attach a balance weight corresponding to the
measured weight value on the position (inner) KNOCK TYPE
indicated by the wheel balancer. BALANCE WEIGHT WHEEL CENTER OF
BALANCE WEIGHT
Caution
• Do not attach 3 or more balance weights.
• One balance weight must not exceed 60g
TIRE
{2.12 oz}, and a total of 2 balance weights
must not exceed 100g {3.53 oz}. POSITION INDICATED 02-12
BY WHEEL BALANCE
INNER SIDE OUTER SIDE

am8rrw00001347

Remaining Amount of Unbalance Confirmation

1. After installing the outer and inner balance weights, operate the wheel balancer again.
2. Confirm that the remaining unbalance does not exceed following on either side.
Standard
Outer Inner
18 inch wheel 10 g {0.35 oz} 6 g {0.21 oz}
20 inch wheel 6 g {0.21 oz} 4 g {0.14 oz}

End Of Sie
TIRE PRESSURE ADJUSTMENT (WITH TPMS)
id021200800300
1. Use of a digital gauge is recommended for accurate measurement of the air pressure.
2. Tire pressure lowers gradually as time passes. Due to this, monthly air pressure inspection is recommended.
3. Perform tire pressure adjustment before driving. (When tires are cold.)
• Tire pressure will increase after driving because the internal temperature of the tire is high. If tire pressure
is adjusted to specifications when the internal temperature of the tire is high, tire pressure will decrease
when the internal temperature of the tire decreases to the same level as ambient temperature. If the tire
pressure is lower than the lower-limit pressure, the TPMS warning light may illuminate.
• Even though the air pressure is adjusted to specifications, the indicated air pressure may be higher than the
specified value when the internal temperature of the tire is higher than ambient temperature. (Example: Air
pressure changes approx. 10 kPa {0.1 kgf/cm2, 1.5 psi} when the temperature changes 10 °C {18 °F})

Caution
• In an area or a season with varying temperatures, tire pressure will change due to ambient
temperature change. If the tire pressure is lower than the lower-limit pressure due to low ambient
temperature, the TPMS warning light may illuminate. Adjust the pressure when the TPMS warning
light illuminates.
• Do not tilt or use excessive side force when checking air pressure or inflating the tire with air.
Which can provide enough leverage to easily bend or break the wheel unit.
• To prevent damage to the valve area of
the wheel unit or pressure loss during air
pressure adjustment, use a type B tool TYPE A TYPE B
with a round end as shown in the figure,
not a type A tool.

End Of Sie
WM: TIRE PRESSURE MONITORING SYSTEM

acxuuw00001039

02-12–3
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WHEEL AND TIRES

WHEEL UNIT ID REGISTRATION
id021200800400

Note
• After the wheel unit replacement, registration of the wheel unit identification codes must be performed.
• ID registration can be done using the M-MDS, or not using the M-MDS.

Using M-MDS
1. After the vehicle is identified, select the following items from the initialization screen of the M-MDS.
• This function is available for only the IDS (notebook PC).
1. Select the “Body” tab.
2. Select the “TPMS Functions”.
3. Select the “Wheel Unit ID Registration”.
2. Leave the vehicle with the engine off for 15 min or more.
3. Verify that the TPMS warning light turns on and off in 0.5 s cycles repeatedly.
4. Drive the vehicle at a speed of 25 km/h {15.5 mph} or more for 10 min to implement the wheel unit ID
registration.

Note
• If the ID registration is not completed even after driving the vehicle for 10 min or more at a speed of 25
km/h {15.5 mph} or more, the TPMS warning light flashes.

5. Verify that the TPMS warning light turns off.

Note
• If the wheel unit ID registration cannot be performed after driving 10 min or more, refer to the symptom
troubleshooting procedure.

Without Using M-MDS

1. Turn the ignition switch to the ON position, then turn it off.
2. Leave the vehicle with the engine off for 15 min or more.
3. Drive the vehicle at a speed of 25 km/h {15.5 mph} or more for 10 min or more.
4. After driving for 10 min, verify that the TPMS warning light does not flash and is not illuminated.
End Of Sie
WM: WHEEL SENSOR

02-12–4
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WHEEL AND TIRES

WHEEL UNIT REMOVAL/INSTALLATION
id021200800600
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. When replacing wheel unit (s), register the new wheel unit ID (s). (See 02-12-4 WHEEL UNIT ID
REGISTRATION.)

Note
• If the wheel unit is replaced with a new one, the ID registration must be performed. When the ID
registration is finished, the data for the new wheel unit is displayed on the M-MDS.
02-12
1

2 R

3 R

7.5—8.5
{77—86, 67—75}

5 R

6
R

N·m {kgf·cm, in·lbf}

acxuuw00001040

1 Valve cap 4 Wheel unit

2 Valve core (See 02-12-5 Wheel Unit Removal Note.)
(See 02-12-5 Valve Core Removal Note.) (See 02-12-6 Wheel Unit Installation Note.)
3 Valve nut and washer 5 Seal washer
6 Seal

Valve Core Removal Note

1. Remove the valve core of the wheel unit, and bleed the air from the tire.

Wheel Unit Removal Note

1. Push the tire valve completely into the tire.

Caution
• Breaking the tire bead with the wheel unit installed normally could damage the unit. Be sure to
always push the wheel unit so that it is completely inside the tire to prevent any damage.

2. Position the shoe (bead breaker) of the tire changer 10—20 mm {0.40—0.78 in} from the outer edge of the
wheel, and break both tire beads.
3. Remove the bead from one side of the wheel.
4. Remove the wheel unit.

02-12–5
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WHEEL AND TIRES

Wheel Unit Installation Note
1. Insert the wheel unit valve into the valve hole so
that the polyurethane foam side faces the rim. WHEEL UNIT

Note
• Maintain the wheel unit in contact with the
rim, then start manually to screw the valve
nut for a few turns.

2. Install the nut from the outer side of the wheel.

3. Tighten the valve nut slowly (15 rpm max.) to 8.0 VALVE HOLE
N·m {82 kgf·cm, 71 in·lbf} in one rotation.
acxuuw00001041
Caution
• Do not retighten the valve nut after the
initial operation.

4. Set the tire changer so that it is 45° away (point A)

from the valve hole. POINT A

Caution
• Do not position the tire changer near the
tire valve to avoid any damage to the
wheel unit.

TIRE ROTATION
VALVE DIRECTION
45°

VALVE

THE ARM OF
THE TIRE
45° CHANGER

POINT A TIRE ROTATION DIRECTION

acxuuw00001042

5. Fill the tire with air and verify the valve nut
tightening torque.
TYPE A TYPE B
Caution
• To prevent damage to the valve area of
the wheel unit or charging loss during air
pressure adjustment, use a type B tool
with a round end as shown in the figure,
not a type A tool.

End Of Sie

acxuuw00001043

02-12–6
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FRONT SUSPENSION
02-13 FRONT SUSPENSION
FRONT SUSPENSION FRONT STABILIZER
LOCATION INDEX. . . . . . . . . . . . . . . . . 02-13–2 REMOVAL/INSTALLATION . . . . . . . . . . 02-13–9
FRONT SHOCK ABSORBER AND Front Stabilizer
SPRING Installation Note . . . . . . . . . . . . . . . . . 02-13–10
REMOVAL/INSTALLATION. . . . . . . . . . 02-13–3 Stabilizer Bushing
Front Shock Absorber and Coil Installation Note . . . . . . . . . . . . . . . . . 02-13–10
Spring Removal Note . . . . . . . . . . . . . 02-13–4 Stabilizer Bracket
Front Shock Absorber and Coil Installation Note . . . . . . . . . . . . . . . . . 02-13–10 02-13
Spring Installation Note . . . . . . . . . . . 02-13–4 STABILIZER CONTROL LINK
FRONT SHOCK ABSORBER AND INSPECTION . . . . . . . . . . . . . . . . . . . . . 02-13–10
SPRING FRONT CROSSMEMBER
DISASSEMBLY/ASSEMBLY . . . . . . . . . 02-13–5 REMOVAL/INSTALLATION . . . . . . . . . . 02-13–11
Piston Rod Nut Tie-rod End Ball Joint
Disassembly Note . . . . . . . . . . . . . . . 02-13–6 Removal Note . . . . . . . . . . . . . . . . . . . 02-13–12
Coil Spring Assembly Note . . . . . . . . . 02-13–6 Steering Gear And Linkage, Front
Upper Spring Seat Stabilizer, Front Lower Arm and
Assembly Note . . . . . . . . . . . . . . . . . . 02-13–6 Front Crossmember Component
Mounting Rubber Removal Note . . . . . . . . . . . . . . . . . . . 02-13–12
Assembly Note . . . . . . . . . . . . . . . . . . 02-13–7 Front Crossmember Mounting Rubber
FRONT SHOCK ABSORBER (Front) Installation Note. . . . . . . . . . . . 02-13–14
INSPECTION . . . . . . . . . . . . . . . . . . . . . 02-13–7 Front Crossmember Mounting Rubber
FRONT SHOCK ABSORBER (Rear) Installation Note . . . . . . . . . . . . 02-13–14
DISPOSAL. . . . . . . . . . . . . . . . . . . . . . . 02-13–7 Steering Gear And Linkage, Front
FRONT LOWER ARM Stabilizer, Front Lower Arm and Front
REMOVAL/INSTALLATION. . . . . . . . . . 02-13–8 Crossmember Component
FRONT LOWER Installation Note . . . . . . . . . . . . . . . . . 02-13–14
ARM INSPECTION . . . . . . . . . . . . . . . . 02-13–8 TRANSVERSE MEMBER
REMOVAL/INSTALLATION . . . . . . . . . . 02-13–15

End of Toc
WM: SUSPENSION

02-13–1
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FRONT SUSPENSION
FRONT SUSPENSION LOCATION INDEX
id021300800100

5 4
7

ac9uuw00000774

1 Front shock absorber and coil spring 4 Front stabilizer

(See 02-13-3 FRONT SHOCK ABSORBER (See 02-13-9 FRONT STABILIZER
AND SPRING REMOVAL/INSTALLATION.) REMOVAL/INSTALLATION.)
(See 02-13-5 FRONT SHOCK ABSORBER 5 Stabilizer control link
AND SPRING DISASSEMBLY/ASSEMBLY.) (See 02-13-10 STABILIZER CONTROL LINK
2 Front shock absorber INSPECTION.)
(See 02-13-7 FRONT SHOCK ABSORBER 6 Front crossmember
INSPECTION.) (See 02-13-11 FRONT CROSSMEMBER
(See 02-13-7 FRONT SHOCK ABSORBER REMOVAL/INSTALLATION.)
DISPOSAL.)
7 Transverse member
3 Front lower arm (See 02-13-15 TRANSVERSE MEMBER
(See 02-13-8 FRONT LOWER ARM REMOVAL/INSTALLATION.)
REMOVAL/INSTALLATION.)
(See 02-13-8 FRONT LOWER ARM
INSPECTION.)

End Of Sie
WM: FRONT SHOCK ABSORBER AND SPRING

02-13–2
1890-1U-06H(02-13).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
FRONT SHOCK ABSORBER AND SPRING REMOVAL/INSTALLATION
id021300800200

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.

1. When working on the left side of the vehicle, remove the wiper arm (LH). (See 09-19-4 WINDSHIELD WIPER
MOTOR REMOVAL/INSTALLATION.)
02-13
2. When working on the left side of the vehicle, partially peel back the cowl grille (LH).
3. When working on the right side of the vehicle, partially peel back the cowl grille (RH).
4. Remove the front fender molding. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Inspect for front wheel alignment, and adjust it as necessary. (See 02-11-2 FRONT WHEEL ALIGNMENT.)

3
4
46.1—62.7 {4.71—6.39, 5
34.1—46.2}

163.0—194.0 {16.7—19.7, 120.3—143.0}

2

7.8—10.8 N·m {80—110

kgf·cm, 70—95 in·lbf}

N·m {kgf·m, ft·lbf}

ac9uuw00001711

1 ABS wheel-speed sensor 6 Front shock absorber and coil spring

(See 02-13-4 Front Shock Absorber and Coil Spring
2 Brake hose clip
Removal Note.)
3 Cap (See 02-13-4 Front Shock Absorber and Coil Spring
4 Nut Installation Note.)
5 Stiffener

02-13–3
1890-1U-06H(02-13).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
Front Shock Absorber and Coil Spring Removal Note
1. Make a mark on the body aligning the
identification mark on the mounting rubber before
removing the front shock absorber and coil
spring.

MARK

IDENTIFICATION
MARK

am8rrw00001819

Front Shock Absorber and Coil Spring Installation Note

1. Align the identification mark on the mounting
rubber with the mark on the body.

MARK

IDENTIFICATION
MARK

am8rrw00001819

2. Install the front shock absorber installation bolts

from the following directions.
— LH: Insert the bolts from the vehicle rear
— RH: Insert the bolts from the vehicle front
End Of Sie

ac9uuw00000714

02-13–4
1890-1U-06H(02-13).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
FRONT SHOCK ABSORBER AND SPRING DISASSEMBLY/ASSEMBLY
id021300800300

Warning
• Removing/installing the piston rod nut is dangerous. The shock absorber and spring could fly off
under tremendous pressure and cause serious injury or death. Secure the shock absorber in the
SSTs before removing the piston rod nut.

1. Remove the front shock absorber and coil spring. (See 02-13-3 FRONT SHOCK ABSORBER AND SPRING
REMOVAL/INSTALLATION.)
2. Disassemble in the order indicated in the table.
02-13
3. Assemble in the reverse order of disassemble.
89.2—127.4
{9.10—12.99,
R SST 65.8—93.9}
1
2
SST
9 3

10 5

8
11 RUBBER
GREASE

GREASE

N·m {kgf·m, ft·lbf}

am8rrw00001359

1 Piston rod nut 6 Upper spring seat rubber

(See 02-13-6 Piston Rod Nut Disassembly 7 Dust boot
Note.) 8 Bound stopper
2 Washer 9 Coil spring
3 Mounting rubber (See 02-13-6 Coil Spring Assembly Note.)
(See 02-13-7 Mounting Rubber Assembly 10 Lower spring seat
Note.)
11 Front shock absorber
4 Bearing
5 Upper spring seat
(See 02-13-6 Upper Spring Seat Assembly
Note.)

02-13–5
1890-1U-06H(02-13).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
Piston Rod Nut Disassembly Note

Warning
• Removing the piston rod nut is dangerous. The shock absorber and spring could fly off under
tremendous pressure and cause serious injury or death. Secure the shock absorber in the SSTs
before removing the piston rod nut.

1. Protect the coil spring using a piece of cloth, then set the SSTs.
2. Compress the coil spring using the SSTs, and
49 T034 1A0
remove the piston rod nut.

ampjjw00000644

Coil Spring Assembly Note

1. Compress the coil spring using the SST.
2. Install the shock absorber so that the lower end of
the coil spring is seated on the step of the lower
spring seat.

49 T034 1A0

ampjjw00000536

Upper Spring Seat Assembly Note

1. Install the upper spring seat so that the notch is
facing to the out side of the vehicle.
FRONT

LH RH

NOTCH SPRING SEAT NOTCH

OUT OUT
SIDE SIDE

FRONT SHOCK ABSORBER BOTTOM BRACKET

acxuuw00001061

02-13–6
1890-1U-06H(02-13).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
Mounting Rubber Assembly Note
1. Slide the mounting rubber identification mark
away from the notch of the spring seat and install. FRONT
End Of Sie
WM: FRONT SHOCK ABSORBER

LH RH
IDENTIFICATION
MARK

45˚ ± 5˚
45˚ ± 5˚
02-13
OUT OUT
SIDE SIDE

FRONT SHOCK ABSORBER BOTTOM BRACKET

am8rrw00001820

FRONT SHOCK ABSORBER INSPECTION

id021300800800
1. Remove the front shock absorber. (See 02-13-3 FRONT SHOCK ABSORBER AND SPRING REMOVAL/
INSTALLATION.) (See 02-13-5 FRONT SHOCK ABSORBER AND SPRING DISASSEMBLY/ASSEMBLY.)
2. Inspect for damage and oil leakage.
3. Compress and extend the shock piston at least three times. Verify that the operational force does not change
and that there is no unusual noise.
• If not as specified, replace the front shock absorber.
End Of Sie
FRONT SHOCK ABSORBER DISPOSAL
id021300800900
1. Clamp a shock absorber on a flat surface or with the piston pointing downwards.
2. Drill a 2—3 mm {0.08—0.12 in} hole at a point 20—30 mm {0.8—1.2 in} from the bottom of the tube, so that
the gas can escape.

Warning
• Whenever drilling into a shock absorber, wear protective eye wear. The gas in the shock absorber
is pressurized, and could spray metal chips into the eyes and face when drilling.

3. Turn the hole downwards.

4. The oil can be collected by moving the piston rod
several times up and down and cutting the tube at DRILLING LOCATION
the end. 20—30 mm
5. Dispose of waste oil according to the waste {0.8—1.2 in}
disposal law.
End Of Sie
WM: FRONT LOWER ARM

acxuuw00001104

02-13–7
1890-1U-06H(02-13).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
FRONT LOWER ARM REMOVAL/INSTALLATION
id021300800600
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect for front wheel alignment, and adjust it as necessary. (See 02-11-2 FRONT WHEEL ALIGNMENT.)

7.8—10.8 N·m
47.0—59.0 {80—110 kgf·cm,
{4.80—6.01, 70—95 in·lbf}
34.7—43.5}

1
43.1—58.8
{4.40—5.99,
31.8—43.3}
85.7—100.0
{8.8—10.1,
63.3—73.7}

A
85.7—100.0
{8.8—10.1,
63.3—73.7}

A
3 2
43.1—52.6 SST
{4.40—5.36,
31.8—38.7} 4
5

N·m {kgf·m, ft·lbf}

ac9uuw00001925

1 ABS wheel-speed sensor 4 Front lower arm ball joint

Tie-rod end ball joint 5 Front lower arm
2 (See 02-13-11 FRONT CROSSMEMBER
REMOVAL/INSTALLATION.)
3 Stabilizer control link lower nut

End Of Sie
FRONT LOWER ARM INSPECTION
id021300800700
1. Remove the lower arm from the vehicle.
2. Inspect the arm for bending or damage, and the ball joint for excessive looseness.
• If there is any malfunction, replace the lower arm.
3. Rotate the ball joint stud 5 times. Install the SST
and M6 × 1.0 bolt (bolt length (measured from
below the head): 20 mm {0.79 in}) to the ball joint
stud, measure the rotational torque using a torque
wrench.
• If not within the specification, replace the
lower arm.
M6 x 1.0 BOLT
(BOLT LENGTH
Front lower arm rotational torque (MEASURED FROM
1.4—4.9 N·m {15—49 kgf·cm, 13—43 in·lbf} BELOW THE HEAD):
49 FT01 389
20 mm {0.79 in})
End Of Sie
WM: FRONT STABILIZER am8rrw00001823

02-13–8
1890-1U-06H(02-13).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
FRONT STABILIZER REMOVAL/INSTALLATION
id021300800400
1. Drain the power steering fluid. (See 06-14-3 POWER STEERING FLUID INSPECTION.)
2. Remove the front under cover A and front under cover B. (See 09-16-18 FRONT UNDER COVER REMOVAL/
INSTALLATION.)
3. Remove the middle pipe. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the transverse member. (See 02-13-15 TRANSVERSE MEMBER REMOVAL/INSTALLATION.)
5. Remove the intermediate shaft installation bolt, and disconnect the steering shaft. (See 06-14-6 STEERING
WHEEL AND COLUMN REMOVAL/INSTALLATION.)
6. Remove the front crossmember component. (See 02-13-11 FRONT CROSSMEMBER REMOVAL/
INSTALLATION.) 02-13
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. Inspect for front wheel alignment, and adjust it as necessary. (See 02-11-2 FRONT WHEEL ALIGNMENT.)

43.1—60.8
{4.40—6.19, 31.8—44.8}

4 RUBBER
GREASE

1
GREASE
5
43.1—52.6
{4.40—5.36, 31.8—38.7}

N·m {kgf·m, ft·lbf}

ac9uuw00001926

1 Front stabilizer component 5 Front stabilizer

(See 02-13-10 Front Stabilizer Installation
2 Front stabilizer control link
Note.)
3 Stabilizer bracket
(See 02-13-10 Stabilizer Bracket Installation
Note.)
4 Stabilizer bushing
(See 02-13-10 Stabilizer Bushing Installation
Note.)

02-13–9
1890-1U-06H(02-13).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
Front Stabilizer Installation Note
1. Install the stabilizer bar so that the identification
mark is on the left side of the vehicle.
FRONT

POSITIONING PLATE

IDENTIFICATION
MARK

ac9uuw00002069

Stabilizer Bushing Installation Note

1. Align the outer side of the positioning plate with
the stabilizer bushing.
FRONT

STABILIZER
BUSHING

POSITIONING PLATE
am8rrw00001822

Stabilizer Bracket Installation Note

1. Install the stabilizer bracket so that the arrow is
pointed to the front.
End Of Sie
WM: STABILIZER CONTROL LINK (FRONT/REAR)

ampjjw00000547

STABILIZER CONTROL LINK INSPECTION

id021300800500
1. Remove the stabilizer control link from the vehicle.
2. Inspect for bending and damage.
3. Measure the ball joint starting torque.
(1) Rock the ball joint stud side to side 10 times.
(2) Rotate the ball joint stud 10 times.
(3) Measure the starting torque using a suitable
allen socket and a torque wrench.

Front stabilizer control link ball joint starting

torque
0.2—2.0 N·m {3—20 kgf·cm, 2—17 in·lbf}

• If not as specified, replace the stabilizer control

link.
End Of Sie
WM: FRONT CROSSMEMBER

ac9uuw00001208

02-13–10
1890-1U-06H(02-13).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
FRONT CROSSMEMBER REMOVAL/INSTALLATION
id021300801000

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Drain the power steering fluid. (See 06-14-3 POWER STEERING FLUID INSPECTION.)
2. Remove the front under cover A and front under cover B. (See 09-16-18 FRONT UNDER COVER REMOVAL/
02-13
INSTALLATION.)
3. Remove the middle pipe. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the transverse member. (See 02-13-15 TRANSVERSE MEMBER REMOVAL/INSTALLATION.)
5. Remove the intermediate shaft installation bolt, and disconnect the steering shaft. (See 06-14-6 STEERING
WHEEL AND COLUMN REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Inspect the front wheel alignment, and adjust it as necessary. (See 02-11-2 FRONT WHEEL ALIGNMENT.)

93.1—131.3 {9.6—13.3,
68.7—96.8}
5

7.8—10.8 N·m
R
{80—110 kgf·cm,
70—95 in·lbf}
47.0—59.0 {4.80—6.01,
34.7—43.5}

2 SST
A

3
4
119.6—154.8 {12.20—15.78, 43.1—52.6 {4.40—5.36, 1
88.3—114.1} 31.8—38.7}

96.9—136.0 {9.89—13.86,
7.8—10.8 N·m 71.5—100.3}
A
{80—101 kgf·cm, 43.1—58.8
69.1—88.5 in·lbf} {4.40—5.99,
31.8—43.3}
8
43.1—60.8
{4.40—6.19,
B 31.8—44.8}
D 93.1—116.6
C
{9.50—11.8, 68.7—58.9}
12
7
7.8—10.8 N·m 13
{80—101 kgf·cm,
69.1—88.5 in·lbf} B D

6 9

7.8—10.5 N·m C
{80—107 kgf·cm,
69.1—92.9 in·lbf}
85.7—100 {8.8—10.1,
10 11 63.3—73.7} N·m {kgf·m, ft·lbf}
ac9uuw00000815

1 ABS wheel-speed sensor 2 Tie-rod end ball joint

(See 02-13-12 Tie-rod End Ball Joint Removal
Note.)

02-13–11
1890-1U-06H(02-13).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
3 Front lower arm ball joint 7 Front stabilizer
4 Stabilizer control link lower side nut 8 Steering gear and linkage
5 Steering gear and linkage, front stabilizer, front 9 Front lower arm
lower arm and front crossmember component 10 Front crossmember extension
(See 02-13-12 Steering Gear And Linkage, Front
Stabilizer, Front Lower Arm and Front Crossmember 11 Front crossmember
Component Removal Note.) 12 Front crossmember mounting rubber (front)
(See 02-13-14 Steering Gear And Linkage, Front (See 02-13-14 Front Crossmember Mounting
Stabilizer, Front Lower Arm and Front Crossmember Rubber (Front) Installation Note)
Component Installation Note.) 13 Front crossmember mounting rubber (rear)
6 No.1 engine mount (See 02-13-14 Front Crossmember Mounting
Rubber (Rear) Installation Note)

Tie-rod End Ball Joint Removal Note

1. Remove the tie-rod end ball joint locknut.
2. Disconnect the tie-rod end ball joint using the
SST.

49 T028 3A0

ampjjw00003208

Steering Gear And Linkage, Front Stabilizer, Front Lower Arm and Front Crossmember Component
Removal Note

Warning
• Removing the crossmember component is dangerous. The crossmember component could fall
and cause serious injury or death. Verify that the jack securely supports the crossmember
component.

1. Support the crossmember component with a jack.

acxuuw00001339

02-13–12
1890-1U-06H(02-13).fm 13 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
2. Disconnect the following parts.
— Pressure hose eye connector
— Return hose clamp (steering gear side)
— Pressure hose bracket
— Return hose clamp (tank side)

02-13

ac9uuw00001264

3. Disconnect the oil cooler bracket.

ac9uuw00001265

4. Remove the No.1 engine mounting bracket bolts.

5. Lower the steering gear and linkage, front
stabilizer, front lower arm and front crossmember
component slightly.

acxuuw00001689

02-13–13
1890-1U-06H(02-13).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
Front Crossmember Mounting Rubber (Front) Installation Note
1. Install so that the smaller end of the outer
diameter is pointing up.
UPPER SIDE OF THE VEHICLE

FoMoCo

ac9uuw00000637

Front Crossmember Mounting Rubber (Rear) Installation Note

1. Install so that the larger end of the outer diameter
is pointing up.
UPPER SIDE OF THE VEHICLE

FoMoCo

ac9uuw00000638

Steering Gear And Linkage, Front Stabilizer, Front Lower Arm and Front Crossmember Component
Installation Note
1. Using a jack, install steering gear and linkage,
front stabilizer, and front crossmember
component.

Tightening torque
119.6—154.8 N·m {12.20—15.78 kgf·m,
88.3—114.1 ft·lbf}

acxuuw00001339

2. Connect the following parts.

— Pressure hose eye connector
— Return hose clamp (steering gear side)
— Pressure hose bracket
— Return hose clamp (tank side)

Tightening torque
— Pressure hose eye connector: 29.4—44.1
N·m {3.00—4.49 kgf·m, 21.7—32.5 ft·lbf}

ac9uuw00001264

02-13–14
1890-1U-06H(02-13).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
3. Tighten the bolts on the No.1 engine mounting
bracket in the order of A, B.

Tightening torque
93.1—116.6 N·m {9.50—11.8 kgf·m, 68.7— A
85.9 ft·lbf}

4. Teighten the No.1 engine mount bolt A at the B

specified torque.

Tightening torque 02-13

93.1—116.6 N·m {9.50—11.8 kgf·m, 68.7—
ac9uuw00000786
85.9 ft·lbf}

5. Install the steering gear and linkage, front stabilizer, front lower arm and front crossmember component.
6. Tighten the No.1 engine mount bolt (crossmember side).

Tightening torque
93.1—116.6 N·m {9.50—11.8 kgf·m, 68.7—85.9 ft·lbf}

End Of Sie
TRANSVERSE MEMBER REMOVAL/INSTALLATION
WM: TRANSVERSE MEMBER

id021300801100
1. Remove the transverse member.

TRANSVERSE
MEMBER

93.1—131.3 {9.50—13.38 ,
68.67—96.84}

N·m {kgf·m, ft·lbf}

ac9uuw00000922

02-13–15
1890-1U-06H(02-13).fm 16 ページ ２００６年１２月１９日　火曜日　午前１１時７分

FRONT SUSPENSION
2. Install the transverse member with the
identification mark facing the rear right of the VIEW FROM REAR OF THE VEHICLE
vehicle.
End Of Sie
RH

IDENTIFICATION MARK

ac9uuw00000776

02-13–16
1890-1U-06H(02-14).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
02-14 REAR SUSPENSION
REAR SUSPENSION LOCATION INDEX Caliper Component
[2WD]. . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14–2 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–16
REAR SUSPENSION LOCATION INDEX Rear Trailing Link Component
[AWD] . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14–3 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–16
REAR SHOCK ABSORBER Bracket Installation Note . . . . . . . . . . . . 02-14–16
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–4 TRAILING LINK
REAR SHOCK ABSORBER REMOVAL/INSTALLATION
INSPECTION . . . . . . . . . . . . . . . . . . . . . 02-14–4 [AWD] . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14–16 02-14
REAR SHOCK ABSORBER Caliper Component
DISPOSAL. . . . . . . . . . . . . . . . . . . . . . . 02-14–5 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–17
REAR COIL SPRING Rear Trailing Link Component
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–5 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–18
Rear Shock Absorber Lower Bracket Installation Note . . . . . . . . . . . . 02-14–18
Side Bolt Removal Note . . . . . . . . . . . 02-14–6 REAR STABILIZER
Rear Coil Spring Removal Note . . . . . . 02-14–7 REMOVAL/INSTALLATION [2WD]. . . . . 02-14–19
Rear Coil Spring Installation Note . . . . 02-14–7 Rear Stabilizer Installation Note . . . . . . 02-14–19
REAR LOWER ARM REAR STABILIZER
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–8 REMOVAL/INSTALLATION [AWD] . . . . 02-14–20
REAR LATERAL LINK Rear Stabilizer Component
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–9 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–21
REAR UPPER ARM Rear Stabilizer Installation Note . . . . . . 02-14–21
REMOVAL/INSTALLATION STABILIZER CONTROL
[2WD]. . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14–9 LINK INSPECTION . . . . . . . . . . . . . . . . . 02-14–22
Rear upper arm REAR CROSSMEMBER
Removal Note . . . . . . . . . . . . . . . . . . 02-14–11 REMOVAL/INSTALLATION
Rear upper arm [2WD] . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14–22
Installation Note . . . . . . . . . . . . . . . . . 02-14–11 Caliper Component
REAR UPPER ARM Removal Note . . . . . . . . . . . . . . . . . . . 02-14–23
REMOVAL/INSTALLATION Rear Crossmember Component
[AWD] . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14–12 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–24
Rear upper arm REAR CROSSMEMBER
Removal Note . . . . . . . . . . . . . . . . . . 02-14–13 REMOVAL/INSTALLATION [AWD] . . . . 02-14–24
Rear upper arm Installation Note . . . . . 02-14–14 Caliper Component
TRAILING LINK Removal Note . . . . . . . . . . . . . . . . . . . 02-14–26
REMOVAL/INSTALLATION Rear Differential And Rear
[2WD]. . . . . . . . . . . . . . . . . . . . . . . . . . . 02-14–15 Crossmember Component
Removal Note . . . . . . . . . . . . . . . . . . . 02-14–26

End of Toc
WM: REAR SUSPENSION

02-14–1
1890-1U-06H(02-14).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
REAR SUSPENSION LOCATION INDEX [2WD]
id0214008004a1

3 2

5
9
8

6
4

ac9uuw00002071

1 Rear shock absorber 5 Rear lateral link

(See 02-14-4 REAR SHOCK ABSORBER (See 02-14-9 REAR LATERAL LINK REMOVAL/
REMOVAL/INSTALLATION.) INSTALLATION.)
(See 02-14-4 REAR SHOCK ABSORBER 6 Trailing link
INSPECTION.) (See 02-14-15 TRAILING LINK REMOVAL/
(See 02-14-5 REAR SHOCK ABSORBER INSTALLATION [2WD].)
DISPOSAL.)
7 Rear stabilizer
2 Rear coil spring (See 02-14-19 REAR STABILIZER REMOVAL/
(See 02-14-5 REAR COIL SPRING REMOVAL/ INSTALLATION [2WD].)
INSTALLATION.)
8 Stabilizer control link
3 Rear upper arm (See 02-14-22 STABILIZER CONTROL LINK
(See 02-14-9 REAR UPPER ARM REMOVAL/ INSPECTION.)
INSTALLATION [2WD].)
9 Rear crossmember
4 Rear lower arm (See 02-14-22 REAR CROSSMEMBER
(See 02-14-8 REAR LOWER ARM REMOVAL/ REMOVAL/INSTALLATION [2WD].)
INSTALLATION.)

End Of Sie

02-14–2
1890-1U-06H(02-14).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
REAR SUSPENSION LOCATION INDEX [AWD]
id0214008004a3

02-14
7

3 2

5
9
8
4

ac9uuw00002072

1 Rear shock absorber 5 Rear lateral link

(See 02-14-4 REAR SHOCK ABSORBER (See 02-14-9 REAR LATERAL LINK REMOVAL/
REMOVAL/INSTALLATION.) INSTALLATION.)
(See 02-14-4 REAR SHOCK ABSORBER 6 Trailing link
INSPECTION.) (See 02-14-16 TRAILING LINK REMOVAL/
(See 02-14-5 REAR SHOCK ABSORBER INSTALLATION [AWD].)
DISPOSAL.)
7 Rear stabilizer
2 Rear coil spring (See 02-14-20 REAR STABILIZER REMOVAL/
(See 02-14-5 REAR COIL SPRING REMOVAL/ INSTALLATION [AWD].)
INSTALLATION.)
8 Stabilizer control link
3 Rear upper arm (See 02-14-22 STABILIZER CONTROL LINK
(See 02-14-12 REAR UPPER ARM REMOVAL/ INSPECTION.)
INSTALLATION [AWD].)
9 Rear crossmember
4 Rear lower arm (See 02-14-24 REAR CROSSMEMBER
(See 02-14-8 REAR LOWER ARM REMOVAL/ REMOVAL/INSTALLATION [AWD].)
INSTALLATION.)

End Of Sie
WM: REAR SHOCK ABSORBER

02-14–3
1890-1U-06H(02-14).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
REAR SHOCK ABSORBER REMOVAL/INSTALLATION
id021400801300
1. Remove the trunk side trim. (See 09-17-27 TRUNK SIDE TRIM REMOVAL/INSTALLATION.)
2. Support the rear lower arm using a garage jack.
3. Remove in the order indicated in the table.

ampjjw00000888

4. Install in the reverse order of removal.

21—28.4 {2.15—2.89,
1 15.5—20.9}
2
3
5

93—123 {9.5—12.5,
4 68.6—90.7}
N·m {kgf·m, ft·lbf}
ac9uuw00002073

1 Nut 5 Lower rubber bushing

2 Retainer 6 Retainer
3 Upper rubber bushing 7 Rear shock absorber
4 Bolt and nut (shock absorber lower side)

End Of Sie
REAR SHOCK ABSORBER INSPECTION
id021400801400
1. Remove the rear shock absorber. (See 02-14-4 REAR SHOCK ABSORBER REMOVAL/INSTALLATION.)
2. Inspect for damage and oil leakage.
3. Compress and extend the shock piston at least three times. Verify that the operational force does not change
and that there is no unusual noise.
• If not as specified, replace the rear shock absorber.
End Of Sie

02-14–4
1890-1U-06H(02-14).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
REAR SHOCK ABSORBER DISPOSAL
id021400801500
1. Clamp a shock absorber on a flat surface or with the piston pointing downwards.
2. Drill a 2—3 mm {0.08—0.11 in} hole at a point
20—30 mm {0.8—1.1 in} from the bottom of the
tube, so that the gas can escape.
20—30 mm
Warning {0.8—1.1 in}
• Whenever drilling into a shock absorber,
wear protective eye wear. The gas in the
shock absorber is pressurized, and could 02-14
spray metal chips into the eyes and face
when drilling.

3. Turn the hole downwards.

ac9uuw00001795
4. The oil can be collected by moving the piston rod
several times up and down and cutting the tube at
the end.
5. Dispose of waste oil according to the waste disposal law.
End Of Sie
REAR COIL SPRING REMOVAL/INSTALLATION
WM: REAR COIL SPRING

id021400800700

Caution
• Perform the work using the garage jack.
• When removing/installing the coil spring,
it is necessary to jack up the rear
suspension with unload condition. At
that time, to prevent bending the front of
the vehicle, support the jack up point for
the front crossmember using a jack.

1. Remove the rear ABS wheel-speed sensor. (See

04-18-13 REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [2WD].) (See 04-18-
14 REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [AWD].)
ampjjw00000887
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Inspect the rear wheel alignment. (See 02-11-4 REAR WHEEL ALIGNMENT [2WD].) (See 02-11-5 REAR
WHEEL ALIGNMENT [AWD].)

02-14–5
1890-1U-06H(02-14).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION

43—61 {4.4—6.2, 4
32—44}

1
43—61 {4.4—6.2,
32—44} 120—163 {12.3—16.6,
89—120}

93—123 {9.5—12.5,
2 68.6—90.7}
N·m {kgf·m, ft·lbf}
ac9uuw00000927

1 Rear stabilizer control link upper side nut 3 Rear coil spring
2 Rear shock absorber lower side bolt (See 02-14-7 Rear Coil Spring Removal Note.)
(See 02-14-6 Rear Shock Absorber Lower Side Bolt (See 02-14-7 Rear Coil Spring Installation Note.)
Removal Note.) 4 Rear upper spring seat
5 Rear lower spring seat
6 Bump stopper

Rear Shock Absorber Lower Side Bolt Removal Note

1. Raise the rear trailing link to the unloaded
condition with a jack.
2. Remove the rear shock absorber lower side bolt.

JACK
acxuuw00001976

02-14–6
1890-1U-06H(02-14).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
Rear Coil Spring Removal Note

Warning
• Removing the coil spring is dangerous. The coil spring could fly off, and cause serious injury or
death.

1. Support the rear lower arm inner side using a

garage jack.
2. Loosen the rear lower arm outer side bolt.
3. Lower the rear lower arm inner side slowly.
4. Remove the rear coil spring. 02-14

ac9uuw00000997

Rear Coil Spring Installation Note

Warning
• Installing the coil spring is dangerous. The coil spring could fly off, and cause serious injury or
death.

1. Install the rear coil spring so that the lower end of the rear coil spring is seated on the step of the rear lower
spring seat.
2. Position the jack under the lower arm inner side
and compress the rear coil spring slowly.

ac9uuw00000997

3. Support the rear lower arm outer side and raise

the rear suspension to the unloaded condition
with a separate garage jack.
4. Install the lower arm inner side bolt.

Tightening torque
• 120—163 N·m {12.3—16.6 kgf·m, 89—120
ft·lbf}

5. Tighten the rear lower arm outer side bolt.

Tightening torque
• 120—163 N·m {12.3—16.6 kgf·m, 89—120
ac9uuw00000998

ft·lbf}

End Of Sie
WM: REAR LOWER ARM

02-14–7
1890-1U-06H(02-14).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
REAR LOWER ARM REMOVAL/INSTALLATION
id021400800900
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect for rear wheel alignment, and adjust it as necessary. (See 02-11-4 REAR WHEEL ALIGNMENT
[2WD].) (See 02-11-5 REAR WHEEL ALIGNMENT [AWD].)

C B
120—163 {12.3—16.6,
89—120}

93—123 {9.5—12.5,
68.6—90.7} A 120—163 {12.3—16.6,
B 89—120}

C
2 N·m {kgf·m, ft·lbf}

ac9uuw00000926

1 Rear coil spring component 2 Rear lower arm

(See 02-14-5 REAR COIL SPRING REMOVAL/
INSTALLATION.)

End Of Sie
WM: REAR LATERAL LINKS

02-14–8
1890-1U-06H(02-14).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
REAR LATERAL LINK REMOVAL/INSTALLATION
id021400801200
1. Mark the adjusting cam bolt and cam plate of the rear lateral link.
2. Jack up the rear suspension with unloaded condition.
3. Remove the rear lateral link.

120—163 {12.3—16.6,
89—120}

02-14

120—163 {12.3—16.6,
89—120}

REAR LATERAL LINK

N·m {kgf·m, ft·lbf}
ac9uuw00000933

4. Install the rear lateral link by aligning it with the mark placed during removal.
5. Inspect for rear wheel alignment, and adjust it as necessary. (See 02-11-4 REAR WHEEL ALIGNMENT
[2WD].) (See 02-11-5 REAR WHEEL ALIGNMENT [AWD].)
End Of Sie
REAR UPPER ARM REMOVAL/INSTALLATION [2WD]
WM: REAR UPPER ARM

id0214008008a1

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.

Note
• The rear upper arm inner bolt cannot be tightened completely with the rear upper arm installed to the
vehicle due to the narrow operation space. Therefore, mark the position before removing the rear upper
arm, align the rear crossmember and rear upper arm markings when installing the rear upper arm, and
tighten the rear upper arm inner bolt completely before installing the rear crossmember component to the
vehicle.

1. Remove the presilencer. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)

2. Remove the rear ABS wheel-speed sensor. (See 04-18-13 REAR ABS WHEEL-SPEED SENSOR REMOVAL/
INSTALLATION [2WD].)

02-14–9
1890-1U-06H(02-14).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
3. Support the jack up point for the front
crossmember using a garage jack.

Caution
• Perform the work using a garage jack.
When jacking up the rear suspension
with unloaded condition, to prevent
bending the front of the vehicle, support
the jack up point for the front
crossmember using a garage jack.
4. Jack up the rear suspension with unloaded
condition. ampjjw00000887

Note
• Jacking up the rear suspension with unloaded condition will lighten the force on the bushing and make it
easier to perform the procedure.
5. Mark the rear upper arm and rear crossmember
shown in the figure.
6. Remove the rear coil spring. (See 02-14-5 REAR
COIL SPRING REMOVAL/INSTALLATION.)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.

MARK

am8rrw00001829

9. Inspect for rear wheel alignment, and adjust it as necessary. (See 02-11-4 REAR WHEEL ALIGNMENT
[2WD].)

93—131 {9.5—13.3,
68.6—96.6}

120—163 {12.3—16.6,
89—120}

120—163 {12.3—16.6,
89—120}

93—131 {9.5—13.3,
68.6—96.6}
N·m {kgf·m, ft·lbf}
ac9uuw00002074

02-14–10
1890-1U-06H(02-14).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
.

1 Rear upper arm

(See 02-14-11 Rear upper arm Removal
Note.)
(See 02-14-11 Rear upper arm Installation
Note.)

Rear upper arm Removal Note

1. Remove the rear lateral link installation bolts.
2. Loosen the rear upper arm installation bolts.
3. Support the rear crossmember component using
a mission jack. 02-14

MISSION JACK

am8rrw00001445
4. Remove the crossmember bracket.
5. Loosen the rear crossmember installation nut,
and lower the crossmember approx. 50 mm {2.0
in}.
6. Remove the rear upper arm inner side bolt.
CROSSMEMBER
BRACKET

am8rrw00001446
Rear upper arm Installation Note
1. Place the new rear upper arm together with the
removed rear upper arm and place an alignment
mark on the new rear upper arm. MARK

am8rrw00001830
2. Point the 'IN' mark towards the inside of the
vehicle, align the rear upper arm and rear INNER SIDE OF
crossmember alignment marks, and install the THE VEHICLE
rear upper arm.
3. Tighten the rear upper arm inner side bolt.

Tightening torque
120—163 N·m {12.3—16.6 kgf·m, 89—120
ft·lbf}

4. Install the rear crossmember component. "IN" MARK

ac9uuw00000932
Tightening torque
Rear crossmember installation nut: 93—131
N·m {9.5—13.3 kgf·m, 68.6—96.6 ft·lbf}
Crossmember bracket installation bolt: 18.6—25.5 N·m {1.90—26.0 kgf·m, 13.8—18.8 ft·lbf}
Crossmember bracket installation nut: 18.6—25.5 N·m {1.90—26.0 kgf·m, 13.8—18.8 ft·lbf}

02-14–11
1890-1U-06H(02-14).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
End Of Sie

REAR UPPER ARM REMOVAL/INSTALLATION [AWD]

id0214008008a3

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.

Note
• The rear upper arm inner bolt cannot be tightened completely with the rear upper arm installed to the
vehicle due to the narrow operation space. Therefore, mark the position before removing the rear upper
arm, align the rear crossmember and rear upper arm markings when installing the rear upper arm, and
tighten the rear upper arm inner bolt completely before installing the rear crossmember component to the
vehicle.

1. Remove the presilencer. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)

2. Remove the presilencer insulator.
3. Remove the propeller shaft. (See 03-15-2
PROPELLER SHAFT REMOVAL/ PRESILENCER
INSULATOR
INSTALLATION.)
4. Remove the rear ABS wheel-speed sensor. (See
04-18-15 REAR ABS WHEEL-SPEED SENSOR
INSPECTION [AWD].)
PRESILENCER

8—10
{82—101, 71—88 }
N·m {kgf·cm, in·lbf}
ac9uuw00001931

5. Support the jack up point for the front

crossmember using a garage jack.

Caution
• Perform the work using a garage jack.
When jacking up the rear suspension
with unloaded condition, to prevent
bending the front of the vehicle, support
the jack up point for the front
crossmember using a garage jack.

6. Jack up the rear suspension with unloaded

ampjjw00000887
condition.

Note
• Jacking up the rear suspension with unloaded condition will lighten the force on the bushing and make it
easier to perform the procedure.

7. Mark the rear upper arm and rear crossmember

shown in the figure.
8. Remove the rear coil spring. (See 02-14-5 REAR
COIL SPRING REMOVAL/INSTALLATION.)
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Inspect for rear wheel alignment, and adjust it as
necessary. (See 02-11-5 REAR WHEEL MARK
ALIGNMENT [AWD].)

am8rrw00001829

02-14–12
1890-1U-06H(02-14).fm 13 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION

02-14
93—131 {9.5—13.3,
68.6—96.6}

120—163 {12.3—16.6,
89—120}

120—163 {12.3—16.6,
89—120}

93—131 {9.5—13.3,
68.6—96.6}
N·m {kgf·m, ft·lbf}
ac9uuw00002075

1 Differential oil temperature sensor connector 3 Rear upper arm

2 AWD solenoid connector (See 02-14-13 Rear upper arm Removal Note.)
(See 02-14-14 Rear upper arm Installation Note.)

Rear upper arm Removal Note

1. Remove the rear lateral link installation bolts.
2. Loosen the rear upper arm installation bolts.
3. Support the rear crossmember and differential
component using a mission jack.

MISSION JACK

am8rrw00001445

02-14–13
1890-1U-06H(02-14).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
4. Remove the crossmember bracket.
5. Loosen the rear crossmember installation nut,
and lower the crossmember approx. 50 mm {2.0
in}.
6. Remove the rear upper arm.
CROSSMEMBER
BRACKET

am8rrw00001446

Rear upper arm Installation Note

1. Place the new rear upper arm together with the
removed rear upper arm and place an alignment
mark on the new rear upper arm. MARK

am8rrw00001830

2. Point the 'IN' mark towards the inside of the

vehicle, align the rear upper arm and rear INNER SIDE OF
crossmember alignment marks, and install the THE VEHICLE
rear upper arm.
3. Tighten the rear upper arm inner side bolt.

Tightening torque
120—163 N·m {12.3—16.6 kgf·m, 89—120
ft·lbf}

4. Install the rear crossmember component. "IN" MARK

ac9uuw00000932
Tightening torque
Rear crossmember installation nut: 93—131
N·m {9.5—13.3 kgf·m, 68.6—96.6 ft·lbf}
Crossmember bracket installation bolt: 18.6—25.5 N·m {1.90—26.0 kgf·m, 13.8—18.8 ft·lbf}
Crossmember bracket installation nut: 18.6—25.5 N·m {1.90—26.0 kgf·m, 13.8—18.8 ft·lbf}

End Of Sie
WM: REAR TRAILING LINKS

02-14–14
1890-1U-06H(02-14).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
TRAILING LINK REMOVAL/INSTALLATION [2WD]
id0214008001a1

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Remove the rear ABS wheel-speed sensor. (See 04-18-13 REAR ABS WHEEL-SPEED SENSOR REMOVAL/
INSTALLATION [2WD].)
2. Remove the rear lateral link. (See 02-14-9 REAR LATERAL LINK REMOVAL/INSTALLATION.)
3. Remove the rear coil spring. (See 02-14-5 REAR COIL SPRING REMOVAL/INSTALLATION.) 02-14
4. Remove the rear lower arm. (See 02-14-8 REAR LOWER ARM REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Inspect for rear wheel alignment, and adjust it as necessary. (See 02-11-4 REAR WHEEL ALIGNMENT
[2WD].)

18.6—25.5 A
{1.90—2.60,
13.8—18.8}
B
1
93—123
C {9.5—12.5,
68.6—90.7}
C A 2
B

117—155
{12.0—15.8,
120—163 87—114}
78.4—101.9
{12.3—16.6, {8.0—10.3, 57.9—75.1}
89—120}

3
9

43—61
{4.4—6.2, 32—44}
8

43—61 7 5
{4.4—6.2, 32—44}
4
9.8—14.7 N·m
{100—149 kgf·cm,
87—130 in·lbf}

N·m {kgf·m, ft·lbf}

ac9uuw00002079
.

1 Rear parking brake cable 6 Parking brake component

2 Rear upper arm outer side bolt 7 Rear trailing link component
3 Caliper component (See 02-14-16 Rear Trailing Link Component
(See 02-14-16 Caliper Component Removal Note.) Removal Note.)
4 Disc plate 8 Bracket
(See 04-11-20 REAR BRAKE (DISC) REMOVAL/ (See 02-14-16 Bracket Installation Note.)
INSTALLATION.) 9 Rear trailing link
5 Rear wheel hub component

02-14–15
1890-1U-06H(02-14).fm 16 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
Caliper Component Removal Note
1. Remove the caliper component and suspend it with a cable in a location out of the way.

Rear Trailing Link Component Removal Note

1. Support the rear trailing link using a jack.
2. Remove the rear trailing link.

JACK

ac9uuw00000957

Bracket Installation Note

1. Install the bracket so that its angle as opposed to
the rear trailing link is as shown in the figure.
End Of Sie

5˚24'±5˚

ac9uuw00000958

TRAILING LINK REMOVAL/INSTALLATION [AWD]

id0214008001a3

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Remove the rear ABS wheel-speed sensor. (See 04-18-14 REAR ABS WHEEL-SPEED SENSOR REMOVAL/
INSTALLATION [AWD].)
2. Remove the rear lateral link. (See 02-14-9 REAR LATERAL LINK REMOVAL/INSTALLATION.)
3. Remove the rear coil spring. (See 02-14-5 REAR COIL SPRING REMOVAL/INSTALLATION.)
4. Remove the rear lower arm. (See 02-14-8 REAR LOWER ARM REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Inspect for rear wheel alignment, and adjust it as necessary. (See 02-11-5 REAR WHEEL ALIGNMENT
[AWD].)

02-14–16
1890-1U-06H(02-14).fm 17 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION

B A

18.6—25.5
{1.90—2.60, 13.8—18.8} 02-14

1 C

C 93—123
{9.5—12.5,
A 3 68.6—90.7}
117—155 B
{12.0—15.8,
87—114}
120—163 78.4—101.9
{12.3—16.6, {8.0—10.3, 57.9—75.1}
89—120}

4
10

43—61
{4.4—6.2, 32—44}
9
235—275
{24.0—28.0,
174—202}
7 6 2 R
43—61 8 5
{4.4—6.2, 32—44}
9.8—14.7 N·m
{100—149 kgf·cm,
87—130 in·lbf} N·m {kgf·m, ft·lbf}
ac9uuw00002105

1 Rear parking brake cable 6 Rear wheel hub component

2 Locknut 7 Parking brake component
(See 03-12-5 WHEEL HUB COMPONENT 8 Rear trailing link component
REMOVAL/INSTALLATION [AWD].) (See 02-14-18 Rear Trailing Link Component
3 Rear upper arm outer side bolt Removal Note.)
4 Caliper component 9 Bracket
(See 02-14-17 Caliper Component Removal Note.) (See 02-14-18 Bracket Installation Note.)
5 Disc plate 10 Rear trailing link
(See 04-11-20 REAR BRAKE (DISC) REMOVAL/
INSTALLATION.)

Caliper Component Removal Note

1. Remove the caliper component and suspend it with a cable in a location out of the way.

02-14–17
1890-1U-06H(02-14).fm 18 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
Rear Trailing Link Component Removal Note
1. Support the rear trailing link using a jack.

Caution
• Removing the trailing link is dangerous.
The trailing link could fall and cause
serious injury or death. Verify that the
jack securely supports the trailing link.

2. Separate the rear drive shaft (rear axle side) from

the wheel hub. JACK
3. Remove the rear trailing link.
ac9uuw00000961

Bracket Installation Note

1. Install the bracket so that its angle as opposed to
the rear trailing link is as shown in the figure.
End Of Sie
WM: REAR STABILIZER

5˚24'±5˚

ac9uuw00000962

02-14–18
1890-1U-06H(02-14).fm 19 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
REAR STABILIZER REMOVAL/INSTALLATION [2WD]
id0214008005a1
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

43—61 {4.4—6.2,
32—44} 02-14

RUBBER 43—61

GREASE
{4.4—6.2,
GREASE
32—44}
3
1 4

43—61 {4.4—6.2, 2
32—44}

N·m {kgf·m, ft·lbf}

ac9uuw00000994

1 Rear stabilizer component 3 Bushing

2 Stabilizer bracket 4 Rear stabilizer
(See 02-14-19 Rear Stabilizer Installation Note.)

Rear Stabilizer Installation Note

1. Install the rear stabilizer so that the identification
mark faces the right side of the vehicle.
End Of Sie FRONT OF
THE VEHICLE

IDENTIFICATION
MARK

am8rrw00001449

02-14–19
1890-1U-06H(02-14).fm 20 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
REAR STABILIZER REMOVAL/INSTALLATION [AWD]
id0214008005a3
1. Remove the presilencer. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the presilencer insulator.
3. Remove the propeller shaft. (See 03-15-2
PROPELLER SHAFT REMOVAL/ PRESILENCER
INSULATOR
INSTALLATION.)
4. Remove the rear ABS wheel-speed sensor. (See
04-18-14 REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [AWD].)
5. Remove the rear coil spring. (See 02-14-5 REAR
COIL SPRING REMOVAL/INSTALLATION.) PRESILENCER
6. Remove in the order indicated in the table. 8—10
{82—101, 71—88 }
N·m {kgf·cm, in·lbf}
ac9uuw00001931

7. Install in the reverse order of removal.

43—61 {4.4—6.2,
32—44}

RUBBER 43—61
GREASE

GREASE {4.4—6.2,
32—44}
3

1 4

43—61 {4.4—6.2, 2
32—44}

N·m {kgf·m, ft·lbf}

ac9uuw00000995

1 Rear stabilizer component 3 Bushing

(See 02-14-21 Rear Stabilizer Component Removal 4 Rear stabilizer
Note.) (See 02-14-21 Rear Stabilizer Installation Note.)
2 Stabilizer bracket

02-14–20
1890-1U-06H(02-14).fm 21 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
Rear Stabilizer Component Removal Note
1. Support the rear differential using a jack.

02-14
JACK
ac9uuw00000988

2. Remove the rear differential mounting bracket

(front) installation bolts.
3. Tilt the rear differential towards the front.
4. Remove the rear stabilizer from through the gap
between the rear differential and rear
crossmember.

ampjjw00003054

Rear Stabilizer Installation Note

1. Install the rear stabilizer so that the identification
mark faces the right side of the vehicle.
End Of Sie FRONT OF
WM: STABILIZER CONTROL LINK (FRONT/REAR)
THE VEHICLE

IDENTIFICATION
MARK

am8rrw00001449

02-14–21
1890-1U-06H(02-14).fm 22 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
STABILIZER CONTROL LINK INSPECTION
id021400800300
1. Remove the stabilizer control link from the vehicle. (See 02-14-19 REAR STABILIZER REMOVAL/
INSTALLATION [2WD].) (See 02-14-20 REAR STABILIZER REMOVAL/INSTALLATION [AWD].)
2. Inspect for bending and damage.
3. Measure the ball joint starting torque.
(1) Rock the ball joint stud side to side 10 times.
(2) Rotate the ball joint stud 10 times.
(3) Measure the starting torque using a suitable
Allen socket and a torque wrench.

Rear stabilizer control link ball joint starting

torque
0.2—2.0 N·m {3—20 kgf·cm, 2—17 in·lbf}

• If not as specified, replace the rear stabilizer

control link.
End Of Sie
WM: REAR CROSSMEMBER

ampjjw00002979

REAR CROSSMEMBER REMOVAL/INSTALLATION [2WD]

id0214008010a1

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.

Note
• The rear upper arm inner bolt cannot be tightened completely with the rear upper arm installed to the
vehicle due to the narrow operation space. Therefore, mark the position before removing the rear upper
arm, align the rear crossmember and rear upper arm markings when installing the rear upper arm, and
tighten the rear upper arm inner bolt completely before installing the rear crossmember component to the
vehicle.
1. Support the jack up point for the front
crossmember using a garage jack.
Caution
• Perform the work using a garage jack.
When jacking up the rear suspension
with unloaded condition, to prevent
bending the front of the vehicle, support
the jack up point for the front
crossmember using a garage jack.
2. Jack up the rear suspension with unloaded
condition.
ampjjw00000887

Note
• Jacking up the rear suspension with unloaded condition will lighten the force on the bushing and make it
easier to perform the procedure.
3. Mark the rear upper arm and rear crossmember
shown in the figure.
4. Remove the presilencer. (See 01-15-1 EXHAUST
SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove the rear ABS wheel-speed sensor. (See
04-18-13 REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [2WD].)
6. Remove the rear coil spring. (See 02-14-5 REAR
COIL SPRING REMOVAL/INSTALLATION.) MARK
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. Inspect for rear wheel alignment, and adjust it as
necessary. (See 02-11-4 REAR WHEEL am8rrw00001829

ALIGNMENT [2WD].)

02-14–22
1890-1U-06H(02-14).fm 23 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION

9 93—131 43—61 {4.4—6.2,

{9.5—13.3, 32—44}
68.6—96.6}

RUBBER

GREASE
GREASE
120—163
{12.3—16.6,
89—120}

B 7
A
02-14
4

C
93—131
8
18.6—25.5 {9.5—13.3,
{1.90—2.60, 68.6—96.6} 5
13.8—18.8}

120—163
{12.3—16.6,
89—120}
6 D
E

93—123
{9.5—12.5,
78.4—101.9
68.6—90.7}
{8.00—1039, G
57.83—75.15} 2
18.6—25.5 F
{1.90—2.60,
13.8—18.8} D
E
G
1 F B
A
C
3

120—163 {12.3—16.6, 89—120}

43—61 {4.4—6.2, 32—44} N·m {kgf·m, ft·lbf}
ac9uuw00002100

1 Rear parking brake cable 5 Rear upper arm

(See 04-12-2 PARKING BRAKE REMOVAL/ (See 02-14-9 REAR UPPER ARM REMOVAL/
INSTALLATION [2WD].) INSTALLATION [2WD].)
2 Caliper component 6 Rear lateral link
(See 02-14-23 Caliper Component Removal Note.) (See 02-14-9 REAR LATERAL LINK REMOVAL/
3 Rear lower arm INSTALLATION.)
(See 02-14-8 REAR LOWER ARM REMOVAL/ 7 Rear stabilizer component
INSTALLATION.) (See 02-14-19 REAR STABILIZER REMOVAL/
4 Rear crossmember component INSTALLATION [2WD].)
(See 02-14-24 Rear Crossmember Component 8 Rear crossmember
Removal Note.) 9 Stopper rubber

Caliper Component Removal Note

1. Remove the rear brake caliper component, and suspend it with a cable in a location out of the way.

02-14–23
1890-1U-06H(02-14).fm 24 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
Rear Crossmember Component Removal Note
Warning
• Removing the crossmember is dangerous. The crossmember component could fall and cause
serious injury or death. Verify that the mission jack securely supports the crossmember
component.
1. Support the crossmember component using a
mission jack and remove the installation nuts.
2. Remove the rear crossmember component.
End Of Sie

MISSION JACK

am8rrw00001451
REAR CROSSMEMBER REMOVAL/INSTALLATION [AWD]
id0214008010a3

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
Note
• The rear upper arm inner bolt cannot be tightened completely with the rear upper arm installed to the
vehicle due to the narrow operation space. Therefore, mark the position before removing the rear upper
arm, align the rear crossmember and rear upper arm markings when installing the rear upper arm, and
tighten the rear upper arm inner bolt completely before installing the rear crossmember component to the
vehicle.
1. Support the jack up point for the front
crossmember using a garage jack.

Caution
• Perform the work using a garage jack.
When jacking up the rear suspension
with unloaded condition, to prevent
bending the front of the vehicle, support
the jack up point for the front
crossmember using a garage jack.

2. Jack up the rear suspension with unloaded

ampjjw00000887
condition.

Note
• Jacking up the rear suspension with unloaded condition will lighten the force on the bushing and make it
easier to perform the procedure.

3. Mark the rear upper arm and rear crossmember

shown in the figure.
4. Remove the presilencer. (See 01-15-1 EXHAUST
SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)

MARK

am8rrw00001829

02-14–24
1890-1U-06H(02-14).fm 25 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
5. Remove the presilencer insulator.
6. Remove the propeller shaft. (See 03-15-2
PRESILENCER
PROPELLER SHAFT REMOVAL/ INSULATOR
INSTALLATION.)
7. Remove the rear ABS wheel-speed sensor. (See
04-18-14 REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [AWD].)
8. Remove the rear coil spring. (See 02-14-5 REAR
PRESILENCER
COIL SPRING REMOVAL/INSTALLATION.)
9. Remove in the order indicated in the table. 7.8—10.8
10. Install in the reverse order of removal. {79.2—110.1, 02-14
69.1—95.5} N·m {kgf·m, in·lbf}
11. Inspect for rear wheel alignment, and adjust it as
ac9uuw00001927
necessary. (See 02-11-5 REAR WHEEL
ALIGNMENT [AWD].)

93—131 12
{9.5—13.3, 63—85
68.6—96.6} 120—163 {6.5—8.6,
{12.3—16.6, 47—62}
89—120}
6
12 B
C 11
B
G C
F

78.4—101.9
{8.00—1039,
8 57.83—75.15}
E
3
120—163
D {12.3—16.6,
93—131 89—120}
18.6—25.5 {9.5—13.3,
{1.90—2.60, 68.6—96.6} 63—85 43—61
13.8—18.8} {6.5—8.6, {4.4—6.2,
47—62} 120—163 9 32—44}
{12.3—16.6,
43—61 89—120} 1
{4.4—6.2,
32—44}
10 A

R 2
235—275
18.6—25.5 {24.0—28.0,
G 120—163
{1.90—2.60, {12.3—16.6, 174—202}
GREASE

13.8—18.8} 89—120}
RUBBER
F GREASE
7

E A

D 93—123
{9.5—12.5,
68.6—90.7}

4 5
N·m {kgf·m, ft·lbf}
ac9uuw00002101

1 Rear parking brake cable 3 Caliper component

(See 04-12-7 PARKING BRAKE REMOVAL/ (See 02-14-26 Caliper Component Removal Note.)
INSTALLATION [AWD].) 4 Differential oil temperature sensor connector
2 Locknut 5 AWD solenoid connector
(See 03-12-5 WHEEL HUB COMPONENT
REMOVAL/INSTALLATION [AWD].)

02-14–25
1890-1U-06H(02-14).fm 26 ページ ２００６年１２月１９日　火曜日　午前１１時９分

REAR SUSPENSION
6 Rear lower arm 9 Rear lateral link
(See 02-14-8 REAR LOWER ARM REMOVAL/ (See 02-14-9 REAR LATERAL LINK REMOVAL/
INSTALLATION.) INSTALLATION.)
7 Rear differential and rear crossmember component 10 Rear stabilizer component
(See 02-14-26 Rear Differential And Rear (See 02-14-20 REAR STABILIZER REMOVAL/
Crossmember Component Removal Note.) INSTALLATION [AWD].)
8 Rear upper arm 11 Rear crossmember
(See 02-14-12 REAR UPPER ARM REMOVAL/ 12 Stopper rubber
INSTALLATION [AWD].)

Caliper Component Removal Note

1. Remove the rear brake caliper component, and suspend it with a cable in a location out of the way.

Rear Differential And Rear Crossmember Component Removal Note

Warning
• Removing the crossmember is dangerous. The crossmember component could fall and cause
serious injury or death. Verify that the mission jack securely supports the crossmember
component.

1. Support the crossmember component using a

mission jack and remove the installation nuts.
2. Remove the rear crossmember component.
End Of Sie

MISSION JACK

am8rrw00001451

02-14–26
1890-1U-06H(02-50).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時１１分

TECHNICAL DATA
02-50 TECHNICAL DATA
SUSPENSION TECHNICAL DATA . . . . . 02-50–1

End of Toc
SUSPENSION TECHNICAL DATA
WM: SUSPENSION

id025000800100
*1
Front wheel alignment [2WD] (Unloaded)
Fuel gauge indication
Item 02-50
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 38°
[Tolerance ±3°] Outer 32°
[Tolerance ±4 {±0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°18′±0°32′
Caster angle*2[Tolerance ±1°] 3°01′ 3°02′ 3°03′ 3°04′
Camber angle*2[Tolerance ±1°] −0°19′ −0°20′ −0°21′
Steering axis inclination (Reference value) 11°31′ 11°32′ 11°33′ 11°34′ 11°35′

*1 : Engine coolant and engine oil are at specified level. Jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.

Front wheel alignment [AWD] (Unloaded)*1

Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 38°
[Tolerance ±3°] Outer 32°
[Tolerance ±4 {±0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°18′±0°32′
Caster angle*2 [Tolerance ±1°] 3°02′ 3°03′ 3°04′ 3°05′
Camber angle [Tolerance ±1°]
*2 −0°19′ −0°20′ −0°21′
Steering axis inclination (Reference value) 11°31′ 11°32′ 11°33′ 11°34′ 11°35′

*1 : Engine coolant and engine oil are at specified level. Jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.

Rear wheel alignment [2WD] (Unloaded) *1

Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
[Tolerance ±4 {±0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°09′±0°18′
Camber angle *2 (Reference value) -0°27′ -0°28′ -0°30′ -0°31′ -0°33′
[Tolerance ±1°]
Thrust angle (Reference value)
0°
[Tolerance ±0°48′]
*1 : Engine coolant and engine oil are at specified level. Jack and tools are in designated position.
*2
: Difference between left and right must not exceed 1°30′.

02-50–1
1890-1U-06H(02-50).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時１１分

TECHNICAL DATA
Rear wheel alignment [AWD] (Unloaded) *1
Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
[Tolerance ±4 {±0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°09′±0°18′
Camber angle *2 (Reference value) -0°26′ -0°27′ -0°29′ -0°30′ -0°32′
[Tolerance ±1°]
Thrust angle (Reference value)
0°
[Tolerance ±0°48′]
*1
: Engine coolant and engine oil are at specified level. Jack and tools are in designated position.
*2
: Difference between left and right must not exceed 1°30′.

Suspension
Item Specification
Front lower arm rotational torque 1.0—4.9 N·m {11—49 kgf·cm, 9—43 in·lbf}
Front stabilizer control link ball joint starting torque 0.2—2.0 N·m {3—20 kgf·cm, 2—17 in·lbf}
Rear stabilizer control link ball joint starting torque 0.2—2.0 N·m {3—20 kgf·cm, 2—17 in·lbf}

Wheel and tires

Item Specification
Size P245/60R18 104H P245/50R20 102V
Air pressure Front
Tire 250 {36} 230 {34}
(kPa {psi}) Rear
Remaining treed (mm {in}) 1.6 {0.07}
Size 18×7 1/2J 20×7 1/2J
Material Aluminum alloy
Wheel Wheel offset (mm {in}) 45 {1.8}
Wheel pitch circle
(mm {in}) 114.3 {4.5}
diameter
Standard
tire Wheel and tire runout Lateral direction 2.0 {0.08}
(mm {in}) Radial direction 1.5 {0.06}
Adhesive-type*1: 10 {0.35} max. Adhesive-type*1: 6 {0.21} max.
Knock-type*2: 6 {0.21} max. Knock-type*2: 4 {0.14} max.
*1: Total weight exceeds 160 g {5.65 oz}.
Wheel and tire imbalance (g {oz}) *2
: One balance weight: 60 g {2.12 oz} max. If the total weight
exceeds 100 g {3.53 oz} on one side, rebalance after moving the
tire around on the rim. Do not use three or more balance
weights.
Wheel nut tightening torque (N·m {kgf·m, ft·bf}) 107.8—147.0 {11.0—14.9, 79.6—108.4}
Size T115/90D 18
Tire Air pressure (kPa {psi}) 420 {60}
Remaining treed (mm {in}) 1.6 {0.07}
Size 18×4T
Material Steel
Temporary
Wheel Wheel offset (mm {in}) 40 {1.57}
spare tire
Wheel pitch circle
(mm {in}) 114.3 {4.5}
diameter
Wheel and tire runout Lateral direction 2.0 {0.08}
(mm {in}) Radial direction 1.5 {0.06}
Wheel nut tightening torque (N·m {kgf·m, ft·bf}) 107.8—147.0 {11.0—14.9, 79.6—108.4}

End Of Sie

02-50–2
1890-1U-06H(02-60).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時１２分

SERVICE TOOLS
02-60 SERVICE TOOLS
SUSPENSION SST . . . . . . . . . . . . . . . . . 02-60–1

End of Toc
SUSPENSION SST
WM: SUSPENSION

id026000800100

49 T034 1A0 49 T028 3A0 49 FT01 389

Coil spring Ball Joint Puller Preload adapter 02-60

compressor set set

End Of Sie

02-60–1
1890-1U-06H(03-02).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時１３分

DRIVELINE/AXLE 03SECTION

Toc of SCT
ON-BOARD DIAGNOSTIC . . . . 03-02 DIFFERENTIAL . . . . . . . . . . . . 03-14
SYMPTOM PROPELLER SHAFT . . . . . . . . 03-15
TROUBLESHOOTING . . . . . . 03-03 TRANSFER . . . . . . . . . . . . . . . 03-16
GENERAL PROCEDURES . . . . 03-10 ALL WHEEL DRIVE 03-02
FRONT AXLE . . . . . . . . . . . . . . 03-11 (AWD). . . . . . . . . . . . . . . . . . . 03-19
REAR AXLE . . . . . . . . . . . . . . . 03-12 TECHNICAL DATA . . . . . . . . . . 03-50
DRIVE SHAFT . . . . . . . . . . . . . . 03-13 SERVICE TOOLS . . . . . . . . . . . 03-60
Toc of SCT
03-02 ON-BOARD DIAGNOSTIC
ELECTRONIC AWD CONTROL Reading DTCs Procedure . . . . . . . . . . 03-02–2
SYSTEM WIRING DIAGRAM . . . . . . . . . 03-02–1 Clearing DTCs Procedures . . . . . . . . . 03-02–2
ELECTRONIC AWD CONTROL DTC Table . . . . . . . . . . . . . . . . . . . . . . 03-02–2
SYSTEM ON-BOARD DTC P1887. . . . . . . . . . . . . . . . . . . . . . . . 03-02–3
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 03-02–2 DTC P1888. . . . . . . . . . . . . . . . . . . . . . . . 03-02–5

End of Toc
ELECTRONIC AWD CONTROL SYSTEM WIRING DIAGRAM
WM: DIFFERENTIAL (FF/FR)

id030200800100

AWD CM ELECTRONIC CONTROL

COUPLING

K O

IGNITION SWITCH
I
P

AWD SOLENOID

CAN_H PCM
G
DIFFERENTIAL OIL A
TEMPERATURE
SENSOR C
H
CAN_L
BATTERY CAN DRIVER
OTHER SYSTEMS
(TCM, DSC/RSC HU/CM,
N INSTRUMENT CLUSTER ETC.)

ac9uuw00001453

End Of Sie

03-02–1
1890-1U-06H(03-02).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時１３分

ON-BOARD DIAGNOSTIC
ELECTRONIC AWD CONTROL SYSTEM ON-BOARD DIAGNOSIS
id030200800200
Reading DTCs Procedure
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “4X4”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “4X4”.
3. Select “Self Test”.
ac9uuw00001090
3. Verify the DTC according to the directions on the
screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
4. After completion of repairs, clear all DTCs stored in the AWD CM. (See 03-02-2 Clearing DTCs Procedures)
Clearing DTCs Procedures
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “4X4”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “4X4”.
3. Select “Self Test”.
ac9uuw00001090
3. Verify the DTC according to the directions on the
screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.

DTC Table
DTC Diagnosis system component Page
P1887 AWD solenoid circuit (See 03-02-3 DTC P1887)
P1888 Differential oil temperature sensor circuit (See 03-02-5 DTC P1888)
U0073 CAN system communication error (See 09-02L-8 DTC TABLE [MULTIPLEX
COMMUNICATION SYSTEM])
U0100 Communication error to PCM (See 09-02L-8 DTC TABLE [MULTIPLEX
COMMUNICATION SYSTEM])
U0101 Communication error to TCM (See 09-02L-8 DTC TABLE [MULTIPLEX
COMMUNICATION SYSTEM])
U0121 Communication error to DSC/RSC HU/CM (See 09-02L-8 DTC TABLE [MULTIPLEX
COMMUNICATION SYSTEM])
U0155 Communication error to instrument cluster (See 09-02L-8 DTC TABLE [MULTIPLEX
COMMUNICATION SYSTEM])

End Of Sie

03-02–2
1890-1U-06H(03-02).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時１３分

ON-BOARD DIAGNOSTIC
DTC P1887
id030200800300

DTC P1887 AWD solenoid circuit

• Current detection circuit in AWD CM detects current above specification for more than specified period.
• AWD CM detects that AWD solenoid control signal differs from current detected at current detection
DETECTION
circuit for more than specified period.
CONDITION
• Relay voltage detection circuit detects that voltage does not concur with relay ON/OFF signal for more
than specified period.
• Open circuit or short to GND in harness between battery and AWD CM terminal K
• Open circuit or short to GND between AWD CM terminal O and AWD solenoid terminal B
• Open circuit or short to GND between AWD CM terminal P and AWD solenoid terminal A
POSSIBLE • Open or short circuit in AWD CM internal circuit
CAUSE • ENG B+ (10A) fuse malfunction
• AWD solenoid malfunction 03-02
• AWD CM malfunction
• Poor connection of connectors (female terminals)
FUSE (ENG B+ (10A)) AWD CM

RELAY AWD SOLENOID

K

O B
BATTERY

P A

AWD CM CONNECTOR AWD SOLENOID CONNECTOR

O M K I G E C A
P N L J H F D B B A

03-02–3
1890-1U-06H(03-02).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時１３分

ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT AWD SOLENOID CONDITION Yes Go to next step.
• Turn ignition key to OFF. No Replace AWD solenoid, then go to Step 7.
• Disconnect AWD solenoid connector.
• Inspect AWD solenoid.
(See 03-19-12 AWD SOLENOID
INSPECTION)
• Is it okay?
2 INSPECT AWD SOLENOID TO AWD CM Yes Go to next step.
(POWER SUPPLY CIRCUIT) FOR OPEN No Repair or replace harness for open circuit between AWD
CIRCUIT CM and AWD solenoid, then go to Step 7.
• Disconnect AWD CM connector.
• Inspect for continuity between AWD CM
terminal O and AWD solenoid terminal B.
• Is there continuity?
3 INSPECT AWD SOLENOID TO AWD CM Yes Repair or replace harness for short to ground between AWD
(POWER SUPPLY CIRCUIT) FOR SHORT TO CM and AWD solenoid, then go to Step 7.
GROUND No Go to next step.
• Inspect for continuity between AWD CM
terminal O and ground.
• Is there continuity?
4 INSPECT AWD SOLENOID TO AWD CM Yes Go to next step.
(GROUND CIRCUIT) FOR OPEN CIRCUIT No Repair or replace harness for open circuit between AWD
• Inspect for continuity between AWD CM CM and AWD solenoid, then go to Step 7.
terminal P and AWD solenoid terminal A.
• Is there continuity?
5 INSPECT AWD SOLENOID TO AWD CM Yes Repair or replace harness for short to ground between AWD
(GROUND CIRCUIT) FOR SHORT TO CM and AWD solenoid, then go to Step 7.
GROUND No Go to next step.
• Inspect for continuity between AWD CM
terminal P and ground.
• Is there continuity?
6 INSPECT AWD CM POWER SUPPLY CIRCUIT Yes Go to step 7.
FOR OPEN CIRCUIT No Repair or replace harness for open circuit between AWD
• Measure voltage between AWD CM terminal CM and battery, then go to next step.
K and ground.
• Is voltage B+?
7 INSPECT FUSE CONDITION Yes Go to next step.
• Turn ignition key to OFF. No Replace fuse, then go to Step 9.
• Is ENG B+ (10A) fuse okay?
8 VERIFY TROUBLESHOOTING COMPLETED Yes Replace AWD CM, then go to next step.
• Make sure to reconnect all disconnected No Go to next step.
connectors.
• Clear DTC from memory.
(See 03-02-2 ELECTRONIC AWD
CONTROL SYSTEM ON-BOARD
DIAGNOSIS)
• Drive vehicle.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection.
• Is there any other DTC present? No Troubleshooting completed.

End Of Sie

03-02–4
1890-1U-06H(03-02).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時１３分

ON-BOARD DIAGNOSTIC
DTC P1888
id030200800400

DTC P1888 Differential oil temperature sensor circuit

DETECTION
• Differential oil temperature sensor voltage monitor circuit detects abnormal input voltage.
CONDITION
• Open circuit, or short to battery or GND between AWD CM terminal A and differential oil temperature
sensor terminal A
• Open circuit or short to battery between AWD CM terminal C and differential oil temperature sensor
POSSIBLE
terminal B
CAUSE
• Differential oil temperature sensor malfunction
• AWD CM malfunction
• Poor connection of connectors (female terminals)

AWD CM DIFFERENTIAL OIL 03-02

TEMPERATURE SENSOR

A A

C B

AWD CM CONNECTOR DIFFERENTIAL OIL TEMPERATURE

SENSOR CONNECTOR

O M K I G E C A
B A
P N L J H F D B

03-02–5
1890-1U-06H(03-02).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時１３分

ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DIFFERENTIAL OIL Yes Go to next step.
TEMPERATURE SENSOR CONDITION No Replace differential oil temperature sensor, then go to Step
• Turn ignition key to OFF. 7.
• Disconnect differential oil temperature
sensor connector.
• Is it okay?
2 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Go to next step.
TEMPERATURE SENSOR FOR OPEN No Repair or replace harness for open circuit between AWD
CIRCUIT CM and differential oil temperature sensor, then go to Step
• Disconnect AWD CM connector. 7.
• Inspect for continuity between AWD CM
terminal A and differential oil temperature
sensor terminal A.
• Is there continuity?
3 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Repair or replace harness for short to power between AWD
TEMPERATURE SENSOR FOR SHORT TO CM and differential oil temperature sensor, then go to Step
POWER 7.
• Inspect voltage between AWD CM terminal A No Go to next step.
and ground.
• Is voltage B+?
4 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Repair or replace harness for short to ground between AWD
TEMPERATURE SENSOR FOR SHORT TO CM and differential oil temperature sensor, then go to Step
GROUND 7.
• Inspect for continuity between AWD CM No Go to next step.
terminal A and ground.
• Is there continuity?
5 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Go to next step.
TEMPERATURE SENSOR FOR OPEN No Repair or replace harness for open circuit between AWD
CIRCUIT CM and differential oil temperature sensor, then go to Step
• Inspect for continuity between AWD CM 7.
terminal C and differential oil temperature
sensor terminal B.
• Is there continuity?
6 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Repair or replace harness for short to power between AWD
TEMPERATURE SENSOR FOR SHORT TO CM and differential oil temperature sensor, then go to next
POWER step.
• Inspect voltage between AWD CM terminal C No Replace AWD CM, then go to next step.
and ground.
• Is voltage B+?
7 VERIFY TROUBLESHOOTING COMPLETED Yes Replace AWD CM, then go to next step.
• Make sure to reconnect all disconnected No Go to next step.
connectors.
• Clear DTC from memory.
(See 03-02-2 ELECTRONIC AWD
CONTROL SYSTEM ON-BOARD
DIAGNOSIS)
• Drive vehicle.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection.
• Is there any other DTC present? No Troubleshooting completed.

End Of Sie

03-02–6
1890-1U-06H(03-03).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時１６分

SYMPTOM TROUBLESHOOTING
03-03 SYMPTOM TROUBLESHOOTING
ELECTRONIC AWD CONTROL NO.1 FREQUENT FRONT
SYSTEM WIRING DIAGRAM . . . . . . . . 03-03–1 WHEEL SLIP . . . . . . . . . . . . . . . . . . . . . 03-03–3
FOREWORD . . . . . . . . . . . . . . . . . . . . . . 03-03–2 NO.2 TIGHT CORNER BRAKING . . . . . . 03-03–4
SYMPTOM TROUBLESHOOTING . . . . . 03-03–2 NO.3 ABNORMAL NOISE
AND/OR VIBRATION FROM
COUPLING COMPONENT . . . . . . . . . . . 03-03–5

End of Toc
ELECTRONIC AWD CONTROL SYSTEM WIRING DIAGRAM
WM: DIFFERENTIAL (FF/FR)

id030300800100
03-03
AWD CM ELECTRONIC CONTROL
COUPLING

K O

IGNITION SWITCH
I
P

AWD SOLENOID

CAN_H PCM
G
DIFFERENTIAL OIL A
TEMPERATURE
SENSOR C
H
CAN_L
BATTERY CAN DRIVER
OTHER SYSTEMS
(TCM, DSC/RSC HU/CM,
N INSTRUMENT CLUSTER ETC.)

ac9uuw00001453

End Of Sie

03-03–1
1890-1U-06H(03-03).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時１６分

SYMPTOM TROUBLESHOOTING
FOREWORD
id030300800200

Malfunction vehicle delivered

Questionnaire Confirm all customer problems using a questionnaire.

Verify malfunction symptoms Confirm malfunction on actual vehicle.

Symptom troubleshooting DTC inspection Inspect for DTCs using M-MDS.

Perform applicable troubleshooting inspection according to

diagnostic index.

Verify that malfunctions have been repaired

Troubleshooting completed

acxuuw00001066

End Of Sie
SYMPTOM TROUBLESHOOTING
id030300800300
• Verify the symptoms, and perform troubleshooting according to the appropriate number.
No. Symptom Description
1 Frequent front wheel slip Front wheels slip frequently during acceleration on low-friction road.
2 Brakes seem to be applied during tight cornering while driving very
Tight corner braking effect
slowly on paved road.
3 Abnormal noise and/or vibration from There is abnormal noise and/or vibration from coupling unit during
coupling unit driving.

End Of Sie

03-03–2
1890-1U-06H(03-03).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時１６分

SYMPTOM TROUBLESHOOTING
NO.1 FREQUENT FRONT WHEEL SLIP
id030300800400

1 Frequent front wheel slip

[TROUBLESHOOTING HINTS]
• Tire traction performance is extremely poor for given road friction. (AWD system is normal.)
• Improper wheel alignment (AWD system is normal.)
• Rear differential oil temperature is extremely high (Fail-safe condition)
• Differential oil temperature sensor malfunction (Fail-safe condition)
• Compare slip frequency with another vehicle of the same model (under the same road conditions and tire traction
performance).
• Replace tires with others of the same model and perform test under the same road conditions to determine if the
malfunction was caused by tire traction performance.
• Coupling component malfunction
• AWD solenoid malfunction 03-03

Warning
• During simulation driving, vehicle stability may decrease extremely and cause an accident. Be
sure to perform the simulation test driving in a safe area.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY DSC/RSC, PCM, TCM, INSTRUMENT Yes Go to applicable DTC inspection.
CLUSTER AND AWD SYSTEM DTCs No Go to next step.
• Verify DSC/RSC, PCM, TCM, instrument
cluster and AWD system DTCs using the M-
MDS.
• Are there any DTCs present?
2 VERIFY TIRE AIR PRESSURE Yes Go to next step.
• Inspect tire air pressure. No Adjust tire air pressure, then go to next step.
(See 02-12-1 WHEEL AND TIRE (See 02-12-3 TIRE PRESSURE ADJUSTMENT (WITH
SPECIFICATION) TPMS))
• Is it within specification?
3 COMPARE WITH SAME MODEL TIRES Yes Go to next step.
• Install tires of the same model. No AWD system is okay.
• Perform simulation driving.
• Does malfunction recur?
4 COMPARE WITH SAME MODEL VEHICLE Yes AWD system is okay.
• Install tires of malfunctioning vehicle to No Go to next step.
another same model vehicle.
• Perform simulation driving.
• Does malfunction recur?
5 INSPECT AWD SOLENOID Yes Inspect harness between AWD solenoid and AWD CM, then
• Inspect AWD solenoid. go to next step.
(See 03-19-12 AWD SOLENOID No Replace coupling component. (See 03-19-4 COUPLING
INSPECTION) COMPONENT REMOVAL/INSTALLATION.)
• Is coupling component solenoid okay?
6 INSPECT WHEEL ALIGNMENT Yes Replace coupling component. (See 03-19-4 COUPLING
• Inspect wheel alignment. COMPONENT REMOVAL/INSTALLATION.)
(See 02-11-2 FRONT WHEEL ALIGNMENT) No Inspect wheel alignment, and adjust it if necessary.
(See 02-11-5 REAR WHEEL ALIGNMENT
[AWD])
• Is it okay?

End Of Sie

03-03–3
1890-1U-06H(03-03).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時１６分

SYMPTOM TROUBLESHOOTING
NO.2 TIGHT CORNER BRAKING
id030300800500

2 Tight corner braking

[TROUBLESHOOTING HINTS]
• Because the coupling component locks up easily (similar to direct AWD), rotational difference between the front
and rear wheels cannot be absorbed and brake-like phenomenon occurs.
• Due to the coupling component construction, slight tight corner braking effect occurs during tight cornering on a
paved road. (AWD system is okay. Compare with another same model vehicle to determine malfunction.)
• Coupling component malfunction
• AWD solenoid malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY DSC/RSC, PCM, TCM, INSTRUMENT Yes Go to applicable DTC inspection.
CLUSTER AND AWD SYSTEM DTCS No Go to next step.
• Verify DSC/RSC, PCM, TCM, instrument
cluster and AWD system DTCs using the M-
MDS.
• Are there any DTCs present?
2 VERIFY TIRE AIR PRESSURE Yes Go to next step.
• Inspect tire air pressure. No Adjust tire air pressure, then go to next step.
(See 02-12-1 WHEEL AND TIRE (See 02-12-3 TIRE PRESSURE ADJUSTMENT (WITH
SPECIFICATION) TPMS))
• Is it within specification?
3 INSPECT ABS WHEEL-SPEED SENSOR Yes Go to next step.
• Inspect ABS wheel-speed sensor. No Repair or replace malfunctioning part.
• Is it okay?
4 COMPARE WITH SAME MODEL VEHICLE Yes AWD system is okay.
• Perform simulation driving with another same No Go to next step.
model vehicle.
• Does malfunction recur on the same model
vehicle?
5 PERFORM SIMULATION DRIVING WITH AWD Yes Replace coupling component. (See 03-19-4 COUPLING
SOLENOID CONNECTOR DISCONNECTED COMPONENT REMOVAL/INSTALLATION.)
• Turn ignition key OFF. No Go to next step.
• Disconnect AWD solenoid connector.
• Perform simulation driving. (Clear DTC after
simulation driving.)
• Does malfunction recur?
6 INSPECT AWD SOLENOID Yes Go to next step.
• Inspect AWD solenoid. No Replace coupling component. (See 03-19-4 COUPLING
(See 03-19-12 AWD SOLENOID COMPONENT REMOVAL/INSTALLATION.)
INSPECTION)
• Is it okay?
7 INSPECT HARNESS BETWEEN AWD Yes Replace AWD CM. (See 03-19-3 AWD CONTROL
SOLENOID AND AWD CM MODULE REMOVAL/INSTALLATION.)
• Is it okay? No Repair or replace malfunctioning parts.

End Of Sie

03-03–4
1890-1U-06H(03-03).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時１６分

SYMPTOM TROUBLESHOOTING
NO.3 ABNORMAL NOISE AND/OR VIBRATION FROM COUPLING COMPONENT
id030300800600

3 Abnormal noise and/or vibration from coupling component

[TROUBLESHOOTING HINTS]
• Abnormal noise and/or vibration from coupling component during driving
• Propeller shaft is malfunctioning or attached improperly.
• Engine mount or differential mount malfunction
• Resonance of rotating parts on vehicle (engine, propeller shaft, rear differential, tire, etc.)
• Resonance with engine vibration (mainly with exhaust system parts)
• Rear differential malfunction
• Coupling component malfunction

Diagnostic procedure
STEP INSPECTION ACTION 03-03
1 VERIFY DSC/RSC, PCM, TCM, INSTRUMENT Yes Go to applicable DTC inspection.
CLUSTER AND AWD SYSTEM DTCS No Go to next step.
• Verify DSC/RSC, PCM, TCM, instrument
cluster and AWD system DTCs using the M-
MDS.
• Are there any DTCs present?
2 VERIFY INSTALLATION CONDITION OF Yes Go to next step.
VEHICLE PARTS No Repair or replace malfunctioning part.
• Verify installation condition for following:
— Propeller shaft (including bending and
joint operation)
— Center bearing
— Engine mount
— Differential mount
— Hub bearing
— Exhaust system parts
— ABS wheel-speed sensor
• Are they properly installed?
3 DETERMINE IF MALFUNCTION IS CAUSED Yes Reinstall customer’s vehicle tire. Go to next step.
BY REAR DIFFERENTIAL No AWD system is okay.
• Install tires of another brand. Reinstall customer’s vehicle tire.

Note
• When tires of another brand are
installed, the same malfunction can
occur due to conditions different from
customer explanation. Be careful not
to confuse it with customer complaint.
• When change the tires, install the four
tires of same abrasion condition.

• Perform simulation driving at the same

engine speed, gear position, and vehicle
speed that customer vehicle had
malfunction.
• Does the same malfunction occur?
4 INSPECT REAR DIFFERENTIAL Yes Replace coupling component.
• Inspect rear differential for following: No Inspect malfunctioning part and adjust it if necessary.
— Backlash
— Teeth contact
(See 03-14-12 REAR DIFFERENTIAL
ASSEMBLY)
• Are they okay?

End Of Sie

03-03–5
1890-1U-06H(03-10).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時１７分

GENERAL PROCEDURES
03-10 GENERAL PROCEDURES
GENERAL PROCEDURES Suspension Links
(FRONT AND REAR AXLES) . . . . . . . . 03-10–1 Removal/Installation . . . . . . . . . . . . . . 03-10–1
Wheel and Tire Installation . . . . . . . . . 03-10–1 Connector Disconnection . . . . . . . . . . . 03-10–1
Electronic AWD Control
System Parts. . . . . . . . . . . . . . . . . . . . 03-10–1

End of Toc
GENERAL PROCEDURES (FRONT AND REAR AXLES)
WM: DRIVELINE/AXLE

id031000800100
Wheel and Tire Installation
1. When installing the wheels and tires, tighten the 03-10
wheel nuts in a criss-cross pattern to the following
tightening torque.

Tightening torque 1
• 107.8—147.0 N·m {11.0—14.9 kgf·m, 79.6— 4 3
108.4 ft·lbf}
2 5

acxuuw00000002

Suspension Links Removal/Installation

1. For the joint sections with rubber bushings, raise the vehicle using a lift, and then temporarily tighten the
installation bolts and nuts. Lower the vehicle to the ground and tighten them completely with the specified
torque.

Connector Disconnection
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)

Electronic AWD Control System Parts

1. After servicing the electronic AWD control system parts, verify that no DTC has been stored. Clear any DTCs
remaining in the memory.
End Of Sie

03-10–1
1890-1U-06H(03-11).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時１８分

FRONT AXLE
03-11 FRONT AXLE
FRONT AXLE LOCATION INDEX. . . . . . 03-11–1 Brake Caliper Removal Note . . . . . . . . . 03-11–4
FRONT WHEEL HUB BOLT Wheel Hub Removal Note. . . . . . . . . . . 03-11–5
REPLACEMENT . . . . . . . . . . . . . . . . . . 03-11–2 Wheel Bearing Removal Note . . . . . . . . 03-11–5
WHEEL HUB, STEERING KNUCKLE Dust Cover Removal Note. . . . . . . . . . . 03-11–5
INSPECTION . . . . . . . . . . . . . . . . . . . . . 03-11–2 Wheel Hub Bolt Removal Note . . . . . . . 03-11–6
Wheel Bearing Excessive Wheel Hub Bolt Installation Note . . . . . 03-11–6
Play Inspection. . . . . . . . . . . . . . . . . . 03-11–2 Dust Cover Installation Note . . . . . . . . . 03-11–6
WHEEL HUB, STEERING KNUCKLE Wheel Bearing Installation Note . . . . . . 03-11–7
REMOVAL/INSTALLATION. . . . . . . . . . 03-11–3 Wheel Hub Installation Note . . . . . . . . . 03-11–7
Locknut Removal Note . . . . . . . . . . . . . 03-11–4 Locknut Installation Note . . . . . . . . . . . . 03-11–7
03-11
End of Toc
FRONT AXLE LOCATION INDEX
WM: FRONT AXLE

id031100800100

ampjjw00003178

1 Wheel hub bolt 2 Wheel hub, steering knuckle

(See 03-11-2 FRONT WHEEL HUB BOLT (See 03-11-2 WHEEL HUB, STEERING KNUCKLE
REPLACEMENT.) INSPECTION.)
(See 03-11-3 WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION.)

End Of Sie

03-11–1
1890-1U-06H(03-11).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時１８分

FRONT AXLE
FRONT WHEEL HUB BOLT REPLACEMENT
id031100800200
1. Remove the brake calliper component from the steering knuckle and suspend it out of the way using a cable.
2. Remove the disc plate.
3. Tap the dust cover (the part shown in the figure)
with a chisel lightly and bend the processing point
back to the steering knuckle side.

BEND THIS PART

ac9uuw00001194

4. Remove the wheel hub bolt using the SST as

shown in the figure.
5. Place a new wheel hub bolt in the wheel hub.

49 T028 3A0
ac9uuw00001195

6. Install the wheel hub by placing a proper sized

washer on the hub, and tightening the nut as HUB BOLT
shown in the figure.
End Of Sie

WHEEL NUT
WHEEL NUT
BRASS BAR WASHER

ac9uuw00001196

WHEEL HUB, STEERING KNUCKLE INSPECTION

id031100800300
Wheel Bearing Excessive Play Inspection
1. Install the magnetic base and dial gauge as
shown in the figure and measure the wheel
bearing axial excessive play.
• If it exceeds the maximum specification,
replace the wheel hub bearing.

Front wheel bearing maximum play

0.05 mm {0.002 in}

End Of Sie

acxuuw00001097

03-11–2
1890-1U-06H(03-11).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時１８分

FRONT AXLE
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION
id031100800400

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, disconnect the ABS wheel-speed sensor connector (axle side) and fix
the wiring harness to an appropriate place where it will not be pulled by mistake while servicing
the vehicle.

1. Remove the front ABS wheel-speed sensor. (See 04-18-11 FRONT ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal. 03-11
4. After installation, inspect the front wheel alignment and adjust it if necessary. (See 02-11-2 FRONT WHEEL
ALIGNMENT.)

14 SST R
163.0—194.0
{16.63—19.78,
13
120.3—143.0}
7 R
SST
12

R
11 SST
107.8—127.4 R 10
1 {11.00—12.99,
79.51—93.96}
47.0—59.0
9
C {4.80—6.01, R 15
34.7—43.5}

43.1—58.8
C {4.40—5.99,
A
6 31.8—43.3}

SST 4
5
9.8—14.7 N·m
{100—149 kgf·cm,
B
87—130 in·lbf}

43.1—52.6 B
{4.40—5.36,
31.8—38.7}
A 2 R
8 235.2—274.4
{23.99—27.98,
173.5—202.3}

3
N·m {kgf·m, ft·lbf}
ac9uuw00001193

1 Brake hose clip 6 Tie-rod end ball joint

2 Locknut (See 02-13-11 FRONT CROSSMEMBER
(See 03-11-4 Locknut Removal Note.) REMOVAL/INSTALLATION.)
(See 03-11-7 Locknut Installation Note.) 7 Nut (front shock absorber lower side)
3 Brake caliper component 8 Front lower arm ball joint
(See 03-11-4 Brake Caliper Removal Note.) 9 Wheel hub, steering knuckle component
4 Disc plate 10 Wheel hub
5 Stabilizer control link (lower side) (See 03-11-5 Wheel Hub Removal Note.)
(See 03-11-7 Wheel Hub Installation Note.)

03-11–3
1890-1U-06H(03-11).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時１８分

FRONT AXLE
11 Retaining ring 14 Steering knuckle
12 Wheel bearing 15 Wheel hub bolt
(See 03-11-5 Wheel Bearing Removal Note.) (See 03-11-6 Wheel Hub Bolt Removal Note.)
(See 03-11-7 Wheel Bearing Installation Note.) (See 03-11-6 Wheel Hub Bolt Installation Note.)
13 Dust cover
(See 03-11-5 Dust Cover Removal Note.)
(See 03-11-6 Dust Cover Installation Note.)

Locknut Removal Note

1. Lock the hub by applying the brakes.
2. Knock the crimped portion of the locknut outward
using a small chisel and a hammer.
3. Remove the locknut.
4. Install a spare nut onto the drive shaft so that the
nut is flush with the end of the drive shaft.

ac9uuw00001756

5. Tap the nut with a copper hammer to loosen the

drive shaft from the front wheel hub.
6. Separate the drive shaft from the wheel hub.

ac9uuw00001757

Brake Caliper Removal Note

1. Remove the brake caliper component from the
steering knuckle and suspend it out of the way
using a cable.

ac9uuw00001758

03-11–4
1890-1U-06H(03-11).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時１８分

FRONT AXLE
Wheel Hub Removal Note
1. Remove the wheel hub using the SSTs.
Substitution SST 49 G033 105
49 G033 102
• 49 G033 105
Outer diameter: 37—43 mm {1.5—1.6 in}

49 F026 103

ac9uuw00001759 03-11
2. If the bearing inner race remains on the front
wheel hub component, grind a section of the
bearing inner race until approx. 0.5 mm {0.02 in}
remains. Then remove it using a chisel.

acxjjw00001127

Wheel Bearing Removal Note

1. Remove the wheel bearing using the SSTs.
Substitution SST 49 G033 106
• 49 G033 106 49 G033 102
Outer diameter: 54—63 mm {2.2—2.4 in}

49 F026 103

ac9uuw00001761

Dust Cover Removal Note

Note
• The dust cover does not need to be removed unless it is being replaced.

1. Mark the dust cover and steering knuckle for

proper installation.

MARKING

ac9uuw00001762

03-11–5
1890-1U-06H(03-11).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時１８分

FRONT AXLE
2. Remove the dust cover using a chisel.

ac9uuw00001763

Wheel Hub Bolt Removal Note

Note
• The hub bolts do not need to be removed unless they are being replaced.

1. Remove the hub bolt using a press.

ac9uuw00001764

Wheel Hub Bolt Installation Note

1. Install the new hub bolt using a press.

acxjjw00001128

Dust Cover Installation Note

1. Mark the new dust cover in the same way as the
removed one.
2. Align the marks of the new dust cover and the
knuckle.

ac9uuw00001766

03-11–6
1890-1U-06H(03-11).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時１８分

FRONT AXLE
3. Install the new dust cover using the SSTs.
Substitution SST STEEL PLATE
• 49 G033 107A 49 G033 107A
Inner diameter: 98—108 mm {3.9—4.2 in}
Tube with board thickness 3 mm {0.2 in} or
more
• 49 F027 009
Outer diameter: 77—82 mm {3.1—3.2 in}

49 F027 009

ac9uuw00001767
03-11
Wheel Bearing Installation Note
1. Install the new wheel bearing using the SSTs.
Substitution SST 49 F027 003
• 49 F027 004
Outer diameter: 78—83 mm {3.1—3.2 in} 49 F027 004
• 49 F027 009
Outer diameter: 77—82 mm {3.1—3.2 in}

49 F027 009
ac9uuw00001768

Wheel Hub Installation Note

1. Install the wheel hub using the SSTs.
Substitution SST 49 G033 102
• 49 G033 105
Outer diameter: 39—48 mm {1.6—1.8 in} 49 G033 105
• 49 B025 004
Outer diameter: 54—63 mm {2.2—2.4 in}

49 B025 004

ac9uuw00001769

Locknut Installation Note

1. Install a new locknut and stake it as shown.
End Of Sie 0.5 mm {0.02 in} OR MORE

ac9uuw00001770

03-11–7
1890-1U-06H(03-12).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時２０分

REAR AXLE
03-12 REAR AXLE
REAR AXLE LOCATION INDEX . . . . . . . 03-12–1 Brake Caliper Component
REAR WHEEL HUB BOLT Removal Note . . . . . . . . . . . . . . . . . . . 03-12–3
REPLACEMENT . . . . . . . . . . . . . . . . . . 03-12–2 Wheel Hub Bolt Removal Note . . . . . . . 03-12–4
WHEEL HUB COMPONENT Wheel Hub Bolt Installation Note . . . . . 03-12–4
INSPECTION . . . . . . . . . . . . . . . . . . . . . 03-12–2 WHEEL HUB COMPONENT
Wheel Bearing Excessive REMOVAL/INSTALLATION
Play Inspection. . . . . . . . . . . . . . . . . . 03-12–2 [AWD] . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-12–5
WHEEL HUB COMPONENT Locknut Removal Note . . . . . . . . . . . . . 03-12–6
REMOVAL/INSTALLATION Rear Trailing Link and Rear Wheel
[2WD]. . . . . . . . . . . . . . . . . . . . . . . . . . . 03-12–3 Hub Component
Removal Note . . . . . . . . . . . . . . . . . . . 03-12–6 03-12
Locknut Installation Note . . . . . . . . . . . . 03-12–6

End of Toc
REAR AXLE LOCATION INDEX
WM: REAR AXLE

id031200800100

2WD AWD

1
1

2
2
ac9uuw00001236

1 Wheel hub bolt 2 Wheel hub component

(See 03-12-2 REAR WHEEL HUB BOLT (See 03-12-2 WHEEL HUB COMPONENT
REPLACEMENT.) INSPECTION.)
(See 03-12-3 WHEEL HUB COMPONENT
REMOVAL/INSTALLATION [2WD].)
(See 03-12-5 WHEEL HUB COMPONENT
REMOVAL/INSTALLATION [AWD].)

End Of Sie

03-12–1
1890-1U-06H(03-12).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時２０分

REAR AXLE
REAR WHEEL HUB BOLT REPLACEMENT
id031200800200
1. Remove the brake calliper component and suspend it out of the way using a cable.
2. Remove the disc plate.
3. Remove the parking brake shoe.
4. Remove the wheel hub bolt using the SST as
shown in the figure.
5. Place a new wheel hub bolt in the wheel hub.

49 T028 3A0

ac9uuw00002136

6. Install the wheel hub by placing a proper sized

washer on the hub, and tightening the nut as HUB BOLT
shown in the figure.
End Of Sie

WHEEL NUT
BRASS BAR WHEEL NUT WASHER

ac9uuw00002109

WHEEL HUB COMPONENT INSPECTION

id031200800300
Wheel Bearing Excessive Play Inspection
1. Install the magnetic base and dial gauge as
shown in the figure and measure the wheel
bearing axial excessive play.
• If it exceeds the maximum specification,
replace the wheel hub component.

Rear wheel bearing maximum play

0.05 mm {0.002 in}

End Of Sie

ac9uuw00001357

03-12–2
1890-1U-06H(03-12).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時２０分

REAR AXLE
WHEEL HUB COMPONENT REMOVAL/INSTALLATION [2WD]
id0312008004a1

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, disconnect the ABS wheel-speed sensor connector (body side) and fix
the wiring harness to an appropriate place where it will not be pulled by mistake while servicing
the vehicle.

1. Remove the rear ABS wheel-speed sensor. (See 04-18-13 REAR ABS WHEEL-SPEED SENSOR REMOVAL/
INSTALLATION [2WD].)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal. 03-12
117—155
1 {12.0—15.8,
18.6—25.5 86.3—114.3}
{1.90—2.60,
13.8—18.8}

78.4—101.9
A {8.00—10.39, 2
57.83—75.15}

43—61
5 9.8—14.7 N·m
{100—149 kgf·cm,
{4.4—6.2, 87—130 in·lbf}
32—44}
R 6
4
N·m {kgf·m, ft·lbf}
ac9uuw00001238

1 Parking brake end cable 3 Disc plate

(See 04-12-2 PARKING BRAKE REMOVAL/ (See 04-11-20 REAR BRAKE (DISC) REMOVAL/
INSTALLATION [2WD].) INSTALLATION
2 Brake caliper component 4 Wheel hub component
(See 03-12-3 Brake Caliper Component Removal 5 Parking brake component
Note.)
6 Wheel hub bolt
(See 03-12-4 Wheel Hub Bolt Removal Note.)
(See 03-12-4 Wheel Hub Bolt Installation Note.)

Brake Caliper Component Removal Note

1. Remove the brake caliper component from the
trailing link and suspend it out of the way using a
cable.

ac9uuw00001239

03-12–3
1890-1U-06H(03-12).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時２０分

REAR AXLE
Wheel Hub Bolt Removal Note

Note
• The wheel hub bolts do not need to be removed unless they are being replaced.

1. Remove the wheel hub bolt using a press.

ac9uuw00001240

Wheel Hub Bolt Installation Note

1. Install the new wheel hub bolt using a press.
End Of Sie

ac9uuw00001241

03-12–4
1890-1U-06H(03-12).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時２０分

REAR AXLE
WHEEL HUB COMPONENT REMOVAL/INSTALLATION [AWD]
id0312008004a3

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, disconnect the ABS wheel-speed sensor connector (body side) and fix
the wiring harness to an appropriate place where it will not be pulled by mistake while servicing
the vehicle.

1. Remove the rear ABS wheel-speed sensor. (See 04-18-14 REAR ABS WHEEL-SPEED SENSOR REMOVAL/
INSTALLATION [AWD].)
2. Remove the rear lateral link. (See 02-14-9 REAR LATERAL LINK REMOVAL/INSTALLATION.)
3. Remove the rear coil spring. (See 02-14-5 REAR COIL SPRING REMOVAL/INSTALLATION.) 03-12
4. Remove the rear lower arm. (See 02-14-8 REAR LOWER ARM REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Inspect for rear wheel alignment, and adjust it as necessary. (See 02-11-5 REAR WHEEL ALIGNMENT
[AWD].)

117—155
{12.0—15.8, 3
87—114} A 78.4—101.9
1 {8.00—10.39,
57.83—75.15}

4
6
235—275
{24.0—28.0,
43—61 174—202}
{4.4—6.2, 120—163
32—44} {12.3—16.6, 2 R
89—120}
7
8
R
43—61 5
{4.4—6.2, 32—44}

9.8—14.7 N·m
{99—149 kgf·cm,
87—130 in·lbf} N·m {kgf·m, ft·lbf}
ac9uuw00001243

1 Rear parking brake cable 4 Rear trailing link and rear wheel hub component
2 Locknut (See 03-12-6 Rear Trailing Link and Rear Wheel
(See 03-12-6 Locknut Removal Note.) Hub Component Removal Note.)
(See 03-12-6 Locknut Installation Note.) 5 Disc plate
3 Caliper component 6 Wheel hub component
(See 03-12-3 WHEEL HUB COMPONENT 7 Parking brake shoe component
REMOVAL/INSTALLATION [2WD].)
8 Wheel hub bolt
(See 03-12-3 WHEEL HUB COMPONENT
REMOVAL/INSTALLATION [2WD].)

03-12–5
1890-1U-06H(03-12).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時２０分

REAR AXLE
Locknut Removal Note
1. Lock the hub by applying the brakes.
2. Knock the crimped portion of the locknut outward
using a small chisel and a hammer.
3. Remove the locknut.

ampjjw00004289

Rear Trailing Link and Rear Wheel Hub Component Removal Note
1. Support the rear trailing link and rear wheel hub
component using a jack.

Caution
• Removing the rear trailing link and rear
wheel hub component is dangerous. The
rear trailing link and rear wheel hub
component could fall and cause serious
injury or death. Verify that the jack
securely supports the trailing link.
JACK
2. Separate the rear drive shaft (rear axle side) from
ac9uuw00001244
the wheel hub.
3. Remove the trailing link and rear wheel hub
component.

Locknut Installation Note

1. Install a new locknut and stake it as shown.
End Of Sie

0.5 mm {0.02 in} OR MORE

ac9uuw00001245

03-12–6
1890-1U-06H(03-13).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
03-13 DRIVE SHAFT
DRIVE SHAFT LOCATION INDEX . . . . . 03-13–2 Front Drive Shaft
JOINT SHAFT PRE-INSPECTION . . . . . 03-13–3 Removal Note . . . . . . . . . . . . . . . . . . . 03-13–15
JOINT SHAFT Clip Installation Note . . . . . . . . . . . . . . . 03-13–16
REMOVAL/INSTALLATION Front Drive Shaft
[2WD]. . . . . . . . . . . . . . . . . . . . . . . . . . . 03-13–4 Installation Note . . . . . . . . . . . . . . . . . 03-13–16
Joint Shaft Removal Note . . . . . . . . . . 03-13–5 Locknut Installation Note . . . . . . . . . . . . 03-13–16
Clip Installation Note . . . . . . . . . . . . . . 03-13–5 FRONT DRIVE SHAFT
JOINT SHAFT DISASSEMBLY/ASSEMBLY . . . . . . . . . 03-13–17
REMOVAL/INSTALLATION Boot Band (Wheel Side)
[AWD] . . . . . . . . . . . . . . . . . . . . . . . . . . 03-13–5 Disassembly Note . . . . . . . . . . . . . . . . 03-13–18
Joint Shaft Removal Note . . . . . . . . . . 03-13–6 Boot Band (Transaxle Side) 03-13
Clip Installation Note . . . . . . . . . . . . . . 03-13–7 Disassembly Note . . . . . . . . . . . . . . . . 03-13–18
JOINT SHAFT DISASSEMBLY Outer Ring Disassembly Note . . . . . . . . 03-13–18
[2WD]. . . . . . . . . . . . . . . . . . . . . . . . . . . 03-13–7 Snap Ring, Tripod Joint
Joint Shaft Disassembly Note . . . . . . . 03-13–8 Disassembly Note . . . . . . . . . . . . . . . . 03-13–19
Dust Seal (Axle Side) Boot Disassembly Note . . . . . . . . . . . . . 03-13–19
Disassembly Note . . . . . . . . . . . . . . . 03-13–8 Dynamic Damper Assembly Note . . . . . 03-13–19
Dust Seal (Differential Side) Boot Assembly Note . . . . . . . . . . . . . . . 03-13–20
Disassembly Note . . . . . . . . . . . . . . . 03-13–8 Tripod Joint, Snap Ring
Bearing Disassembly Note. . . . . . . . . . 03-13–8 Assembly Note . . . . . . . . . . . . . . . . . . 03-13–20
JOINT SHAFT DISASSEMBLY Outer Ring Assembly Note . . . . . . . . . . 03-13–20
[AWD] . . . . . . . . . . . . . . . . . . . . . . . . . . 03-13–9 Boot Band (Transaxle Side)
Joint Shaft Disassembly Note . . . . . . . 03-13–9 Assembly Note . . . . . . . . . . . . . . . . . . 03-13–21
Dust Seal (Axle Side) Boot Band (Wheel Side)
Disassembly Note . . . . . . . . . . . . . . . 03-13–9 Assembly Note . . . . . . . . . . . . . . . . . . 03-13–21
Dust Seal (Differential Side) REAR DRIVE
Disassembly Note . . . . . . . . . . . . . . . 03-13–9 SHAFT PRE-INSPECTION. . . . . . . . . . . 03-13–22
Bearing Disassembly Note. . . . . . . . . . 03-13–10 REAR DRIVE SHAFT
JOINT SHAFT ASSEMBLY REMOVAL/INSTALLATION . . . . . . . . . . 03-13–22
[2WD]. . . . . . . . . . . . . . . . . . . . . . . . . . . 03-13–10 Rear Drive Shaft
Bearing Assembly Note . . . . . . . . . . . . 03-13–11 Removal Note . . . . . . . . . . . . . . . . . . . 03-13–23
Dust Seal (Differential Side) Clip Installation Note . . . . . . . . . . . . . . . 03-13–24
Assembly Note . . . . . . . . . . . . . . . . . . 03-13–11 REAR DRIVE SHAFT
Joint Shaft Assembly Note . . . . . . . . . . 03-13–11 DISASSEMBLY/ASSEMBLY . . . . . . . . . 03-13–24
Dust Seal (Axle Side) Boot Band (Wheel Side)
Assembly Note . . . . . . . . . . . . . . . . . . 03-13–11 Disassembly Note . . . . . . . . . . . . . . . . 03-13–25
JOINT SHAFT ASSEMBLY [AWD] . . . . . 03-13–12 Boot Band (Differential Side)
Bearing Assembly Note . . . . . . . . . . . . 03-13–12 Disassembly Note . . . . . . . . . . . . . . . . 03-13–25
Dust Seal (Differential Side) Clip Disassembly Note . . . . . . . . . . . . . 03-13–25
Assembly Note . . . . . . . . . . . . . . . . . . 03-13–13 Snap Ring Disassembly Note . . . . . . . . 03-13–25
Joint Shaft Assembly Note . . . . . . . . . . 03-13–13 Balls, Inner Ring, Cage
Dust Seal (Axle Side) Disassembly Note . . . . . . . . . . . . . . . . 03-13–26
Assembly Note . . . . . . . . . . . . . . . . . . 03-13–13 Boot Assembly Note . . . . . . . . . . . . . . . 03-13–26
FRONT DRIVE Cage, Inner Ring, Balls, Snap Ring
SHAFT PRE-INSPECTION . . . . . . . . . . 03-13–13 Assembly Note . . . . . . . . . . . . . . . . . . 03-13–26
FRONT DRIVE SHAFT Outer Ring, Clip Assembly Note . . . . . . 03-13–27
REMOVAL/INSTALLATION. . . . . . . . . . 03-13–14 Boot Band (Differential Side)
Locknut Removal Note . . . . . . . . . . . . . 03-13–15 Assembly Note . . . . . . . . . . . . . . . . . . 03-13–27
Boot Band (Wheel Side)
Assembly Note . . . . . . . . . . . . . . . . . . 03-13–28

End of Toc
WM: FRONT DRIVE SHAFT

03-13–1
1890-1U-06H(03-13).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
DRIVE SHAFT LOCATION INDEX
id031300800100

2WD
1

AWD

2
ac9uuw00001323

1 Joint shaft 2 Front drive shaft

(See 03-13-3 JOINT SHAFT PRE-INSPECTION) (See 03-13-13 FRONT DRIVE SHAFT PRE-
(See 03-13-4 JOINT SHAFT REMOVAL/ INSPECTION)
INSTALLATION [2WD]) (See 03-13-14 FRONT DRIVE SHAFT REMOVAL/
(See 03-13-5 JOINT SHAFT REMOVAL/ INSTALLATION)
INSTALLATION [AWD]) (See 03-13-17 FRONT DRIVE SHAFT
(See 03-13-7 JOINT SHAFT DISASSEMBLY [2WD]) DISASSEMBLY/ASSEMBLY)
(See 03-13-9 JOINT SHAFT DISASSEMBLY 3 Rear drive shaft (AWD)
[AWD]) (See 03-13-22 REAR DRIVE SHAFT PRE-
(See 03-13-10 JOINT SHAFT ASSEMBLY [2WD]) INSPECTION)
(See 03-13-12 JOINT SHAFT ASSEMBLY [AWD]) (See 03-13-22 REAR DRIVE SHAFT REMOVAL/
INSTALLATION)
(See 03-13-24 REAR DRIVE SHAFT
DISASSEMBLY/ASSEMBLY)

End Of Sie
WM: JOINT SHAFT

03-13–2
1890-1U-06H(03-13).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
JOINT SHAFT PRE-INSPECTION
id031300800800
1. Verify that the joint shaft is not twisted or cracked.
• Replace it as necessary.
2. Turn the joint shaft by hand and verify that the
bearing rotates smoothly and freely.
2WD
• Replace it as necessary.
End Of Sie

03-13

AWD

ac9uuw00001322

03-13–3
1890-1U-06H(03-13).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
JOINT SHAFT REMOVAL/INSTALLATION [2WD]
id0313008009a3

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.

1. Remove the side cover.

2. Remove the front ABS wheel-speed sensor. (See 04-18-11 FRONT ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
34—46 {3.5—4.6,
26—33}
17—23 {1.8—2.3,
13—16}
4 42—62 {4.3—6.3,
31—45}

5 SST
47.0—59.0
{4.80—6.01, R
34.7—43.5}
R 6
2 A

1 SST

43.1—58.8 A
{4.40—5.99,
31.8—43.3} 43.1—52.6
{4.40—5.36,
31.8—38.7}

3
N·m {kgf·m, ft·lbf}

ac9uuw00001638

1 Tie-rod end ball joint 4 Bracket

(See 02-13-11 FRONT CROSSMEMBER 5 Joint shaft
REMOVAL/INSTALLATION) (See 03-13-5 Joint Shaft Removal Note)
2 Stabilizer control link (lower side) 6 Clip
3 Lower arm ball joint (See 03-13-5 Clip Installation Note)

03-13–4
1890-1U-06H(03-13).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Joint Shaft Removal Note
1. Separate the right side drive shaft from the joint
shaft by using the SSTs.
2. Remove the bolts.
3. Pull the joint shaft straight out.

Caution
• The sharp edges of the joint shaft can
slice or puncture the oil seal. Be careful 49 B025 017
when removing the joint shaft from the OR 49 B025 010
transaxle. 49 B025 016
49 0223 630B
ac9uuw00002440 03-13

Clip Installation Note

1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip does
not exceed the specification on installation.
2. After installation, measure the outer diameter. If it
exceeds the specification, repeat Step 1 using a
new clip.
CLIP
Clip outer diameter specification OPENING
34.0 mm {1.34 in} max.

End Of Sie
OUTER
DIAMETER

ac9uuw00001338

JOINT SHAFT REMOVAL/INSTALLATION [AWD]

id0313008009a5

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.

1. Remove the side cover.

2. Remove the front ABS wheel-speed sensor. (See 04-18-11 FRONT ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION.)
3. Remove the middle pipe. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the front pipe. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.

03-13–5
1890-1U-06H(03-13).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT

4 SST
42—62
R {4.3—6.3, 31—45}
R 5
47.0—59.0
{4.80—6.01,
34.7—43.5}

1 SST

43.1—52.6
2 {4.40—5.36, SST
43.1—58.8
{4.40—5.99, 31.8—38.7}
SST R
31.8—43.3} 7
R
6

N·m {kgf·m, ft·lbf}

ac9uuw00001724

1 Tie-rod end ball joint 5 Clip

(See 02-13-11 FRONT CROSSMEMBER (See 03-13-7 Clip Installation Note)
REMOVAL/INSTALLATION) 6 Deflector
2 Stabilizer control link (lower side) (See 03-16-2 TRANSFER OIL SEAL
3 Lower arm ball joint REPLACEMENT)
4 Joint shaft 7 Oil seal
(See 03-13-6 Joint Shaft Removal Note) (See 03-16-2 TRANSFER OIL SEAL
REPLACEMENT)

Joint Shaft Removal Note

1. Separate the right side drive shaft from the joint
shaft by using the SSTs.
2. Remove the nuts.
3. Pull the joint shaft straight out.

Caution
• The sharp edges of the joint shaft can
slice or puncture the oil seal. Be careful 49 B025 017
when removing the joint shaft from the OR 49 B025 010
transaxle. 49 B025 016
49 0223 630B
Note
• If the joint shaft is removed, always replace
ac9uuw00001755

the deflector and oil seal of the transfer with

new ones.

4. Replace the deflector and oil seal. (See 03-16-2 TRANSFER OIL SEAL REPLACEMENT.)

03-13–6
1890-1U-06H(03-13).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Clip Installation Note
1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip does
not exceed the specification on installation.
2. After installation, measure the outer diameter. If it
exceeds the specification, repeat Step 1 using a
new clip.
CLIP
Outer diameter specification OPENING
34.0 mm {1.34 in} max.

End Of Sie
OUTER
DIAMETER
03-13

ac9uuw00001340

JOINT SHAFT DISASSEMBLY [2WD]

id0313008010a3
1. Disassemble in the order indicated in the table. .

4 2
5

SST 7

8
6
1

ac9uuw00001341

1 Cover 5 Snap ring

2 Snap ring 6 Dust seal (differential side)
3 Joint shaft (See 03-13-8 Dust Seal (Differential Side)
(See 03-13-8 Joint Shaft Disassembly Note) Disassembly Note)
4 Dust seal (axle side) 7 Bearing
(See 03-13-8 Dust Seal (Axle Side) Disassembly (See 03-13-8 Bearing Disassembly Note)
Note) 8 Bearing housing

03-13–7
1890-1U-06H(03-13).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Joint Shaft Disassembly Note
1. Remove the joint shaft using a press.

ac9uuw00001407

Dust Seal (Axle Side) Disassembly Note

1. Remove the dust seal using a flathead screwdriver.

Dust Seal (Differential Side) Disassembly Note

1. Remove the dust seal using a flathead screwdriver.

Bearing Disassembly Note

1. Remove the bearing using a press and the SSTs.
Substitution SST
• 49 B014 001
49 B014 001
Outer diameter: 47—55 mm {1.9—2.1 in}
• 49 W034 301
Inner diameter: 67.5—72 mm {2.7—2.8 in}
Inner depth: 30 mm {1.2 in} or more 49 W034 301
Plate thickness: 1 mm {0.04 in} or more
End Of Sie

ac9uuw00001408

03-13–8
1890-1U-06H(03-13).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
JOINT SHAFT DISASSEMBLY [AWD]
id0313008010a5
1. Disassemble in the order indicated in the table. .

4
2
5

SST 7 03-13

8
6

ac9uuw00001349

1 Cover 5 Snap ring

2 Snap ring 6 Dust seal (differential side)
3 Joint shaft (See 03-13-9 Dust Seal (Differential Side)
(See 03-13-9 Joint Shaft Disassembly Note) Disassembly Note)
4 Dust seal (axle side) 7 Bearing
(See 03-13-9 Dust Seal (Axle Side) Disassembly (See 03-13-10 Bearing Disassembly Note)
Note) 8 Bearing housing

Joint Shaft Disassembly Note

1. Remove the joint shaft using a press.

ac9uuw00001342

Dust Seal (Axle Side) Disassembly Note

1. Remove the dust seal using a flathead screwdriver.

Dust Seal (Differential Side) Disassembly Note

1. Remove the dust seal using a flathead screwdriver.

03-13–9
1890-1U-06H(03-13).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Bearing Disassembly Note
1. Remove the bearing using a press and the SSTs.
Substitution SST
• 49 B014 001 49 B014 001
Outer diameter: 47—55 mm {1.9—2.1 in}
• 49 W034 301
Inner diameter: 67.5—72 mm {2.7—2.8 in}
Inner depth: 30 mm {1.2 in} or more 49 W034 301
Plate thickness: 1 mm {0.04 in} or more
End Of Sie

ac9uuw00001343

JOINT SHAFT ASSEMBLY [2WD]

id0313008011a3
1. Assemble in the order indicated in the table.

7 SST R
GREASE

R 6

R 3

SST R 2

SST R 4
GREASE

7.8—10.8 N·m
{80—101 kgf·cm,
69.1—88.5 in·lbf}

SST 5

ac9uuw00001344

1 Bearing housing 5 Joint shaft

2 Bearing (See 03-13-11 Joint Shaft Assembly Note)
(See 03-13-11 Bearing Assembly Note) 6 Snap ring
3 Snap ring 7 Dust seal (axle side)
4 Dust seal (differential side) (See 03-13-11 Dust Seal (Axle Side) Assembly
(See 03-13-11 Dust Seal (Differential Side) Note)
Assembly Note) 8 Cover

03-13–10
1890-1U-06H(03-13).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Bearing Assembly Note
1. Install the new bearing using a press and the
SST.
Substitution SST
• 49 B025 004
Outer diameter: 61 mm {2.4 in} or more 49 B025 004
Inner diameter: 46 mm {1.8 in} or more
Plate thickness: 1 mm {0.04 in} or more

ac9uuw00001409 03-13

Dust Seal (Differential Side) Assembly Note

1. Apply grease to the new dust seal lip.
2. Install the dust seal (differential side) using a
press and the SSTs.
Substitution SST
• 49 B025 004
Outer diameter: 58—59.8 mm {2.2—2.3 in} or 49 B025 004
less
Inner diameter: 53 mm {2.1 in} or more
Inner depth: 7.5 mm {0.30 in} or more
49 W034 301
• 49 W034 301
Inner diameter: 67.5—72.0 mm {2.66—2.83
in}
Inner depth: 8.5 mm {0.33 in} or more
ac9uuw00001410
Plate thickness: 1 mm {0.04 in} or more

Joint Shaft Assembly Note

1. Install the joint shaft using a press and the SST.

49 V001 525

ac9uuw00001411

Dust Seal (Axle Side) Assembly Note

1. Apply grease to the new dust seal lip.
2. Install the dust seal (axle side) using a press and
the SST.
Substitution SST
• 49 B025 004
49 B025 004
Outer diameter: 58—59.8 mm {2.2—2.3 in} or
more
Inner diameter: 53 mm {2.1 in} or more
Inner depth: 7.5 mm {0.30 in} or more
End Of Sie

ac9uuw00001412

03-13–11
1890-1U-06H(03-13).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
JOINT SHAFT ASSEMBLY [AWD]
id0313008011a5
1. Assemble in the order indicated in the table.

7 SST R

GREASE

R 6
R 3
SST R 2

SST R 4
GREASE

8
7.8—10.8 N·m
{80—101 kgf·cm,
69.1—88.5 in·lbf}
SST 5

ac9uuw00001350

1 Bearing housing 5 Joint shaft

2 Bearing (See 03-13-13 Joint Shaft Assembly Note)
(See 03-13-12 Bearing Assembly Note) 6 Snap ring
3 Snap ring 7 Dust seal (axle side)
4 Dust seal (differential side) (See 03-13-13 Dust Seal (Axle Side) Assembly
(See 03-13-13 Dust Seal (Differential Side) Note)
Assembly Note) 8 Cover

Bearing Assembly Note

1. Install the new bearing using a press and the
SST.
Substitution SST
• 49 B025 004
49 B025 004
Outer diameter: 61 mm {2.4 in} or more
Inner diameter: 46 mm {1.8 in} or more
Plate thickness: 1 mm {0.04 in} or more

ac9uuw00001345

03-13–12
1890-1U-06H(03-13).fm 13 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Dust Seal (Differential Side) Assembly Note
1. Apply grease to the new dust seal lip.
2. Install the dust seal (differential side) using a
press and the SSTs.
Substitution SST
• 49 B025 004
Outer diameter: 58—59.8 mm {2.2—2.3 in} or 49 B025 004
less
Inner diameter: 53 mm {2.1 in} or more
Inner depth: 7.5 mm {0.30 in} or more 49 W034 301
• 49 W034 301
Inner diameter: 67.5—72.0 mm {2.66—2.83
in}
03-13
Inner depth: 8.5 mm {0.33 in} or more
ac9uuw00001346
Plate thickness: 1 mm {0.04 in} or more

Joint Shaft Assembly Note

1. Install the joint shaft using a press and the SST.

49 V001 525

ac9uuw00001347

Dust Seal (Axle Side) Assembly Note

1. Apply grease to the new dust seal lip.
2. Install the dust seal (axle side) using a press and
the SST.
Substitution SST
• 49 B025 004
Outer diameter: 58—59.8 mm {2.2—2.3 in} or 49 B025 004
more
Inner diameter: 53 mm {2.1 in} or more
Inner depth: 7.5 mm {0.30 in} or more
End Of Sie
WM: DRIVE SHAFT

ac9uuw00001348

FRONT DRIVE SHAFT PRE-INSPECTION

id031300800200
1. Inspect the dust boot on the drive shaft for cracks,
damage, leaking grease, and looseness in the
boot band.
2. Inspect the drive shaft for bends, cracks, and
wear in the joint or splines.
• Repair or replace the drive shaft or boot/band
as necessary.
End Of Sie

ac9uuw00001246

03-13–13
1890-1U-06H(03-13).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
FRONT DRIVE SHAFT REMOVAL/INSTALLATION
id031300800300

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.

1. Remove the side cover.

2. Remove the front ABS wheel-speed sensor. (See 04-18-11 FRONT ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

6 R
47.0—59.0
{4.80—6.01, R 6 R
34.7—43.5} SST B
5 A

2WD

2 SST

R 1
235.2—274.4 A
{23.99—27.98,
173.5—202.3}
AWD
3
B

43.1—58.8
{4.40—5.99,
31.8—43.3} 43.1—52.6
{4.40—5.36,
31.8—38.7}

4 A

N·m {kgf·m, ft·lbf}

ac9uuw00001355

1 Locknut 4 Front lower arm ball joint

(See 03-13-15 Locknut Removal Note.) 5 Front drive shaft
(See 03-13-16 Locknut Installation Note.) (See 03-13-15 Front Drive Shaft Removal Note.)
2 Tie-rod end ball joint (See 03-13-16 Front Drive Shaft Installation Note.)
(See 02-13-11 FRONT CROSSMEMBER 6 Clip
REMOVAL/INSTALLATION.) (See 03-13-16 Clip Installation Note.)
3 Front stabilizer control link (lower side)

03-13–14
1890-1U-06H(03-13).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Locknut Removal Note
1. Lock the hub by applying the brakes.
2. Knock the crimped portion of the locknut outward
using a small chisel and a hammer.
3. Remove the locknut.

03-13
ac9uuw00001641

Front Drive Shaft Removal Note

1. Install a spare nut onto the drive shaft so that the nut is flush with the end of the drive shaft.
2. Tap the nut with a copper hammer to loosen the
drive shaft from the front wheel hub.
3. Separate the drive shaft from the wheel hub.

Caution
• The sharp edges of the drive shaft can
slice or puncture the oil seal. Be careful
when removing the drive shaft from the
transaxle.

ac9uuw00001642

4. Separate the left side drive shaft from the

transaxle by prying with a bar inserted between
the outer ring and the transaxle, as shown in the
figure.

ac9uuw00001643

5. Separate the right side drive shaft from the joint

shaft by using the SSTs.

49 B025 017
OR 49 B025 010
49 B025 016
49 0223 630B
ac9uuw00002439

03-13–15
1890-1U-06H(03-13).fm 16 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Clip Installation Note
1. Install a new clip onto the drive shaft with the opening facing upward. Ensure that the diameter of the clip does
not exceed the specification on installation.
2. After installation, measure the outer diameter. If it
exceeds the specification, repeat Steps 1—2
using a new clip.
CLIP

Clip outer diameter specification

LH: 34.0 mm {1.34 in} OPENING
RH (joint shaft): 34.0 mm {1.34 in}
OUTER
DIAMETER

ac9uuw00001644

Front Drive Shaft Installation Note

Caution
• The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when installing the
drive shaft to the transaxle.
• The oil seals are damaged easily if this
procedure is not done correctly.

ac9uuw00001645

Left side
1. Insert the drive shaft into the wheel hub.
2. Apply transaxle oil to the oil seal lip.
3. Push the drive shaft into the transaxle.
4. After installation, pull the transaxle side outer ring forward to confirm that the drive shaft is securely held by the
clip.

Right side
1. Insert the drive shaft into the wheel hub.
2. Insert the drive shaft into the joint shaft.
3. After installation, pull the transaxle side outer ring forward to confirm that the drive shaft is securely held by the
clip.

Locknut Installation Note

1. Install a new locknut and stake it as shown.
End Of Sie 0.5 mm {0.02 in} OR MORE

ac9uuw00001646

03-13–16
1890-1U-06H(03-13).fm 17 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY
id031300800400
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

SST 1
R

GREASE
8 R

GREASE
1 SST R
R
2 R
9
03-13

7 RIGHT SIDE
R
10
GREASE

R 8 R 2
5 R 6
3
4
ac9uuw00001358

1 Boot band (wheel side) 6 Snap ring

(See 03-13-18 Boot Band (Wheel Side) (See 03-13-19 Snap Ring, Tripod Joint Disassembly
Disassembly Note.) Note.)
(See 03-13-21 Boot Band (Wheel Side) Assembly (See 03-13-20 Tripod Joint, Snap Ring Assembly
Note.) Note.)
2 Boot band (transaxle side) 7 Tripod joint
(See 03-13-18 Boot Band (Transaxle Side) (See 03-13-19 Snap Ring, Tripod Joint Disassembly
Disassembly Note.) Note.)
(See 03-13-21 Boot Band (Transaxle Side) (See 03-13-20 Tripod Joint, Snap Ring Assembly
Assembly Note.) Note.)
3 Clip 8 Boot
4 Outer ring (See 03-13-19 Boot Disassembly Note.)
(See 03-13-18 Outer Ring Disassembly Note.) (See 03-13-20 Boot Assembly Note.)
(See 03-13-20 Outer Ring Assembly Note.) 9 Shaft and ball joint component
5 Roller cassette 10 Dynamic damper
(See 03-13-19 Dynamic Damper Assembly Note.)

03-13–17
1890-1U-06H(03-13).fm 18 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Boot Band (Wheel Side) Disassembly Note

Note
• The boot band does not need to be removed unless it is being replaced.

1. Remove the boot clamp with end clamp pliers as

shown and discard the clamp.

ac9uuw00001888

Boot Band (Transaxle Side) Disassembly Note

1. Pry up the locking clips using a screwdriver.
2. Pull back the end of the band.

ac9uuw00001889

Outer Ring Disassembly Note

1. Mark the outer ring and the shaft for proper
assembly. MARK

ac9uuw00001890

2. Remove the clip.

3. Remove the outer ring.

ac9uuw00001891

03-13–18
1890-1U-06H(03-13).fm 19 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Snap Ring, Tripod Joint Disassembly Note
1. Mark the shaft and tripod joint for proper assembly.
2. Remove the snap ring using snap-ring pliers.
3. Remove the tripod joint from the shaft.

Caution
• Do not tap the tripod joint with a hammer.

MARK
03-13
ac9uuw00001892

Boot Disassembly Note

Note
• The wheel side boot does not need to be removed unless replacing it or the ball joint and shaft
component.
• Do not strip the tape until the boot is assembled.

1. Wrap the shaft splines with tape.

2. Remove the boot.

TAPE

ac9uuw00001893

Dynamic Damper Assembly Note

1. Install the dynamic damper as shown in the
figure.
DYNAMIC DAMPER
Standard length
290.7—298.7 mm {11.45—11.75 in}

2. Install the new boot band onto the dynamic

damper.

ac9uuw00001359

03-13–19
1890-1U-06H(03-13).fm 20 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Boot Assembly Note

Note
• The wheel side and transaxle side boots are different.

1. Fill the boot (wheel side) with the specified grease.

Caution
• Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.

Grease amount
110—130 g {3.89—4.58 oz}

2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
3. Remove the tape.

Tripod Joint, Snap Ring Assembly Note

1. Align the marks and install the tripod joint using a
bar and a hammer.
2. Install the new snap ring using snap-ring pliers. MARK

Caution
• Be sure the snap ring engages correctly
in the groove of the shaft.

ac9uuw00001894

Outer Ring Assembly Note

1. Fill the outer ring and boot (transaxle side) with the specified grease.

Caution
• Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.

Grease amount
240—260 g {8.48—9.17 oz}

2. Install the roller cassettes.

3. Align the marks, and install the outer ring on to the shaft.
4. Install a new clip.
5. Install the boot.
6. Set the drive shaft to the standard length.

Front drive shaft standard length

LH: 658.7—668.7 mm {25.92—26.30 in}
RH: 630.7—640.7 mm {24.82—25.20 in}

03-13–20
1890-1U-06H(03-13).fm 21 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
7. Release any trapped air from the boots by
carefully lifting up the small end of each boot with
a cloth- wrapped flathead screwdriver.

Caution
• Do not let grease leak.
• Do not damage the boot.

8. Verify that the drive shaft length is within the

standard.

ac9uuw00001895
03-13
Boot Band (Transaxle Side) Assembly Note
1. Fold the band in the direction opposite to the
forward revolving direction of the drive shaft and
use pliers to pull it tight.
2. Lock the end of the band by bending the locking
clips.

Caution
• Install the band into the groove securely.

ac9uuw00001896

Boot Band (Wheel Side) Assembly Note

1. Adjust clearance A by turning the adjusting bolt of
the SST.

Clearance A ADJUSTING BOLT

2.9 mm {0.11 in} A

49 T025 001

ac9uuw00001897

2. Crimp the wheel side small boot band using the

SST. Verify that clearance B is within the B
specification.
• If clearance B is more than the specification,
reduce clearance A of the SST and crimp the
boot again.
• If clearance B is less than the specification, 49 T025 001
replace the boot band, increase clearance A
of the SST, and crimp the new boot.

Clearance B
2.4—2.8 mm {0.095—0.110 in}
ac9uuw00001898

3. Verify that the boot band does not protrude from

the boot band installation area.
• If it does, replace the boot band and repeat Steps 2 and 3.
4. Fill the boot with the repair kit grease.
5. Adjust clearance A by turning the adjusting bolt of the SST.

Clearance A
3.2 mm {0.13 in}

03-13–21
1890-1U-06H(03-13).fm 22 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
6. Crimp the wheel side big boot band using the SST.
7. Verify that clearance B is within the specification.
• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and
crimp the new boot.

Clearance B
2.4—2.8 mm {0.095—0.110 in}

8. Verify that the boot band does not protrude from the boot band installation area.
• If it does, replace the boot band and repeat Steps 7 and 8.
End Of Sie
REAR DRIVE SHAFT PRE-INSPECTION
WM: REAR DRIVE SHAFT

id031300800500
1. Inspect each connecting part for looseness.
• Tighten or replace parts if necessary.
2. Inspect the dust boot on the drive shaft for cracks,
damage, leaking grease, and looseness in the
boot band.
3. Inspect the drive shaft for bends, cracks, and
wear in the joints or splines.
• Repair or replace the drive shaft or boot band
if necessary.
End Of Sie

ac9uuw00001360

REAR DRIVE SHAFT REMOVAL/INSTALLATION

id031300800600

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (wheel side) and fix it to an
appropriate place where the sensor will not be pulled by mistake while the vehicle is being
serviced.

1. Remove the rear ABS wheel-speed sensor. (See 04-18-14 REAR ABS WHEEL-SPEED SENSOR REMOVAL/
INSTALLATION [AWD].)
2. Drain the rear differential oil into a container. (See 03-14-3 DIFFERENTIAL OIL REPLACEMENT.)
3. Remove the rear lateral link. (See 02-14-9 REAR LATERAL LINK REMOVAL/INSTALLATION.)
4. Remove the rear coil spring. (See 02-14-5 REAR COIL SPRING REMOVAL/INSTALLATION.)
5. Remove the rear lower arm. (See 02-14-8 REAR LOWER ARM REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. After installation, add the specified rear differential oil. (See 03-14-3 DIFFERENTIAL OIL REPLACEMENT.)
9. Inspect the rear wheel alignment and adjust it if necessary. (See 02-11-5 REAR WHEEL ALIGNMENT [AWD].)

03-13–22
1890-1U-06H(03-13).fm 23 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT

A
78.4—101.9
R 3 {8.00—1039,
OIL
SST 4 57.83—75.15}
1
R 03-13
2

R
43—61 235—275
120—163 {4.4—6.2, {24.0—28.0,
{12.3—16.6, 32—44} 174—202}
89—120}

43—61
{4.4—6.2,
32—44} N·m {kgf·m, ft·lbf}
ac9uuw00001362

1 Rear trailing link and rear wheel hub component 3 Oil seal
(See 03-12-5 WHEEL HUB COMPONENT (See 03-14-3 OIL SEAL (SIDE GEAR)
REMOVAL/INSTALLATION [AWD].) REPLACEMENT.)
2 Rear drive shaft 4 Clip
(See 03-13-23 Rear Drive Shaft Removal Note.) (See 03-13-24 Clip Installation Note.)

Rear Drive Shaft Removal Note

1. Disengage the rear drive shaft using the SSTs.
49 B025 017
OR
Note
49 B025 016 +
• Be careful not to damage the rear differential
oil seal. 49 0223 630B

49 B025 010
ac9uuw00001363

03-13–23
1890-1U-06H(03-13).fm 24 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Clip Installation Note
1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip does
not exceed the specification on installation.
2. After installation, measure the outer diameter. If it
exceeds the specification, repeat Steps 1—2
using a new clip.
CLIP

Clip outer diameter specification

29.5 mm {1.16 in} max. OPENING

End Of Sie
OUTER
DIAMETER

acxuuw00001259

REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

id031300800700
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

R
3
7

6
R
2
4
9 R
5 2
R
8 R
GREASE

1
9
R
1

10
GREASE

ac9uuw00002478

1 Boot band (wheel side) 6 Balls

(See 03-13-25 Boot Band (Wheel Side) (See 03-13-26 Balls, Inner Ring, Cage Disassembly
Disassembly Note) Note)
(See 03-13-28 Boot Band (Wheel Side) Assembly (See 03-13-26 Cage, Inner Ring, Balls, Snap Ring
Note) Assembly Note)
2 Boot band (differential side) 7 Inner Ring
(See 03-13-25 Boot Band (Differential Side) (See 03-13-26 Balls, Inner Ring, Cage Disassembly
Disassembly Note) Note)
(See 03-13-27 Boot Band (Differential Side) (See 03-13-26 Cage, Inner Ring, Balls, Snap Ring
Assembly Note) Assembly Note)
3 Clip 8 Cage
(See 03-13-25 Clip Disassembly Note) (See 03-13-26 Balls, Inner Ring, Cage Disassembly
(See 03-13-27 Outer Ring, Clip Assembly Note) Note)
4 Outer ring (See 03-13-26 Cage, Inner Ring, Balls, Snap Ring
(See 03-13-27 Outer Ring, Clip Assembly Note) Assembly Note)
5 Snap ring 9 Boot
(See 03-13-25 Snap Ring Disassembly Note) (See 03-13-26 Boot Assembly Note)
(See 03-13-26 Cage, Inner Ring, Balls, Snap Ring 10 Drive shaft, joint component
Assembly Note)

03-13–24
1890-1U-06H(03-13).fm 25 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Boot Band (Wheel Side) Disassembly Note

Note
• The boot band does not need to be removed unless it is being replaced.

1. Remove the boot clamp with end clamp pliers as

shown and discard the clamp.

03-13

ac9uuw00002479

Boot Band (Differential Side) Disassembly Note

1. Pry up the locking clips using a screwdriver.
2. Pull back the end of the band.

ac9uuw00002480

Clip Disassembly Note

1. Mark the drive shaft and outer ring for proper
MARK
assembly.

Caution
• Mark with paint; do not use a punch.

2. Remove the clip.

ac9uuw00002481

Snap Ring Disassembly Note

1. Mark the drive shaft end and inner ring for proper
reassembly.

Caution
• Mark with paint; do not use a punch.

2. Remove the snap ring using snap-ring pliers.

MARK

ac9uuw00002482

03-13–25
1890-1U-06H(03-13).fm 26 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Balls, Inner Ring, Cage Disassembly Note
1. Mark the inner ring and cage for proper reassembly.

Caution
• Mark with paint; do not use a punch.

2. Turn the cage approx. 22.5° and pull the cage

22.5˚
and balls from the inner ring.

ac9uuw00002483

Boot Assembly Note

Note
• The wheel side and differential side boots are different.

1. Fill the wheel side boot with the specified grease.

Caution
• Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.

Grease amount
70—90 g {2.48—3.17 oz}

2. With the splines of the shaft wrapped in tape, install the boot.
3. Remove the tape.

Cage, Inner Ring, Balls, Snap Ring Assembly Note

1. Align the marks and install the balls and cage to
CAGE BALLS
the inner ring in the direction shown in the figure.

Caution
• Install the cage so that the major
diameter is at the same side as the snap
ring groove. If incorrectly installed, the
drive shaft may become disengaged.
SNAP RING INNER
2. Align the marks and install the inner ring to the GROOVE RING MARK
shaft.
3. Install a new snap ring.
acxuuw00001299

03-13–26
1890-1U-06H(03-13).fm 27 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Outer Ring, Clip Assembly Note
1. Fill the outer ring and boot (differential side) with the specified grease.

Caution
• Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.

Grease amount
90—110 g {3.18—3.88 oz}

2. Align the marks, and install the outer ring on to

MARK
the shaft.
3. Install a new clip to the outer ring clip groove.
03-13
4. Install the boot.

ac9uuw00002481

5. Release any trapped air from the boots by

carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.

Caution
• Do not let grease leak.
• Do not damage the boot.

6. Set the drive shaft to the standard length.

Rear drive shaft standard length

LH: 840.3—850.3 mm {33.09—33.47 in}
ac9uuw00002484
RH: 895.3—905.3 mm {35.25—35.64 in}

7. Verify that the drive shaft length is within the standard.

• If not, repeat from Step 5.

Boot Band (Differential Side) Assembly Note

1. Fold the band in the direction opposite to the
forward revolving direction of the drive shaft and
use pliers to pull it tight.
2. Lock the end of the band by bending the locking
clips.

Caution
• Install the band into the groove securely.

ac9uuw00002485

03-13–27
1890-1U-06H(03-13).fm 28 ページ ２００６年１２月１９日　火曜日　午前１１時２１分

DRIVE SHAFT
Boot Band (Wheel Side) Assembly Note
1. Adjust clearance A by turning the adjusting bolt of
the SST.

Clearance A ADJUSTING BOLT

2.9 mm {0.11 in} A

49 T025 001

ac9uuw00002486

2. Crimp the wheel side small boot band using the

SST. Verify that clearance B is within the B
specification.
• If clearance B is more than the specification,
reduce clearance A of the SST and crimp the
boot again.
• If clearance B is less than the specification, 49 T025 001
replace the boot band, increase clearance A
of the SST, and crimp the new boot.

Clearance B
2.4—2.8 mm {0.095—0.110 in}
ac9uuw00002487

3. Verify that the boot band does not protrude from

the boot band installation area.
• If it does, replace the boot band and repeat Steps 2 and 3.
4. Fill the boot with the repair kit grease.
5. Adjust clearance A by turning the adjusting bolt of the SST.

Clearance A
3.2 mm {0.13 in}

6. Crimp the wheel side big boot band using the SST.
7. Verify that clearance B is within the specification.
• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and
crimp the new boot.

Clearance B
2.4—2.8 mm {0.095—0.110 in}

8. Verify that the boot band does not protrude from the boot band installation area.
• If it does, replace the boot band and repeat Steps 7 and 8.
End Of Sie

03-13–28
1890-1U-06H(03-14).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
03-14 DIFFERENTIAL
REAR DIFFERENTIAL Locknut Disassembly Note . . . . . . . . . . 03-14–11
LOCATION INDEX. . . . . . . . . . . . . . . . . 03-14–2 Drive Pinion Disassembly Note . . . . . . . 03-14–11
DIFFERENTIAL OIL Bearing Inner Race (Rear Bearing)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 03-14–2 Disassembly Note . . . . . . . . . . . . . . . . 03-14–11
DIFFERENTIAL OIL Bearing Outer Race
REPLACEMENT . . . . . . . . . . . . . . . . . . 03-14–3 Disassembly Note . . . . . . . . . . . . . . . . 03-14–11
OIL SEAL (SIDE GEAR) Ring Gear Disassembly Note . . . . . . . . 03-14–12
REPLACEMENT . . . . . . . . . . . . . . . . . . 03-14–3 Side Bearing Inner Race
OIL SEAL (COMPANION FLANGE) Disassembly Note . . . . . . . . . . . . . . . . 03-14–12
REPLACEMENT . . . . . . . . . . . . . . . . . . 03-14–4 REAR DIFFERENTIAL
REAR DIFFERENTIAL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 03-14–12 03-14
REMOVAL/INSTALLATION. . . . . . . . . . 03-14–6 Side Bearing Inner Race
Locknut Removal Note . . . . . . . . . . . . . 03-14–7 Assembly Note . . . . . . . . . . . . . . . . . . 03-14–14
Rear Differential Component Thrust washer Assembly Note . . . . . . . 03-14–14
Removal Note . . . . . . . . . . . . . . . . . . 03-14–7 Ring Gear Assembly Note. . . . . . . . . . . 03-14–15
Rear Differential Bearing Outer Race
Component installation Note . . . . . . . 03-14–8 Assembly Note . . . . . . . . . . . . . . . . . . 03-14–15
REAR DIFFERENTIAL Spacer, Bearing Inner Race
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 03-14–9 Assembly Note . . . . . . . . . . . . . . . . . . 03-14–16
Rear Cover Locknut Assembly Note. . . . . . . . . . . . . 03-14–18
Disassembly Note . . . . . . . . . . . . . . . 03-14–10 Adjusting Shim Assembly Note . . . . . . . 03-14–18
Bearing Cap Bearing Cap Assembly Note . . . . . . . . . 03-14–20
Disassembly Note . . . . . . . . . . . . . . . 03-14–10 Rear Cover Assembly Note . . . . . . . . . . 03-14–21
Rear Differential Component Oil Seal Assembly Note . . . . . . . . . . . . 03-14–21
Disassembly Note . . . . . . . . . . . . . . . 03-14–10

End of Toc
WM: DIFFERENTIAL (FF/FR)

03-14–1
1890-1U-06H(03-14).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
REAR DIFFERENTIAL LOCATION INDEX
id031400800300

ac9uuw00001406

1 Differential oil 3 Oil seal (companion flange)

(See 03-14-2 DIFFERENTIAL OIL INSPECTION) (See 03-14-4 OIL SEAL (COMPANION FLANGE)
(See 03-14-3 DIFFERENTIAL OIL REPLACEMENT)
REPLACEMENT) 4 Rear differential
2 Oil seal (side gear) (See 03-14-6 REAR DIFFERENTIAL REMOVAL/
(See 03-14-3 OIL SEAL (SIDE GEAR) INSTALLATION)
REPLACEMENT) (See 03-14-9 REAR DIFFERENTIAL
DISASSEMBLY)
(See 03-14-12 REAR DIFFERENTIAL ASSEMBLY)

End Of Sie
DIFFERENTIAL OIL INSPECTION
id031400800100
1. Place the vehicle on level ground.
2. Remove the filler plug and washer.
3. Verify that the oil is at the brim of the filler plug FILLER PLUG
hole.
4. If it is low, add the specified oil.
5. Install a new washer and the filler plug, and
tighten.

Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7
ft·lbf}

End Of Sie ac9uuw00001461

03-14–2
1890-1U-06H(03-14).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
DIFFERENTIAL OIL REPLACEMENT
id031400800200
1. Place the vehicle on level ground.
2. Remove the filler plug.
3. Remove the drain plug and drain the differential FILLER PLUG
oil into a container.
4. Install a new washer and the drain plug, and
tighten.

Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7
ft·lbf}

5. Add the specified differential oil from the filler plug DRAIN PLUG 03-14
until the level reaches the brim of the plug hole.
ac9uuw00001462

Rear differential oil

Specified oil grade: API service GL-5
Specified oil viscosity: SAE 80W-90
Capacity (approximate quantity): 1.0 L {1.1 US qt, 0.9 Imp qt}

6. After filling with differential oil, perform oil level inspection.

7. Install a new washer and the drain plug, and tighten.

Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7 ft·lbf}

End Of Sie
OIL SEAL (SIDE GEAR) REPLACEMENT
id031400800700
1. Remove the drain plug and the drain differential oil into a container.
2. Install a new washer and the drain plug, and tighten.
3. Remove the rear lateral link. (See 02-14-9 REAR LATERAL LINK REMOVAL/INSTALLATION.)
4. Remove the rear coil spring. (See 02-14-5 REAR COIL SPRING REMOVAL/INSTALLATION.)
5. Remove the rear lower arm. (See 02-14-8 REAR LOWER ARM REMOVAL/INSTALLATION.)
6. Remove the rear trailing link and rear wheel hub component. (See 03-12-5 WHEEL HUB COMPONENT
REMOVAL/INSTALLATION [AWD].)
7. Remove the rear drive shaft. (See 03-13-22 REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
8. Remove the clip from the drive shaft.

Caution
• Wrap the end of a screwdriver with cloth to prevent scratches to the inside of the differential
casing.

9. Remove the oil seal from the differential casing

using a screwdriver.
10. Apply differential oil to the new oil seal lip.

ac9uuw00002076

03-14–3
1890-1U-06H(03-14).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
11. Install the new oil seal to the differential carrier
using the SSTs.
Substitution SST
• 49 G030 796
Outer diameter: 56—60 mm {2.21—2.36 in}
Inner diameter: 49.8 mm {2.0 in} or more
Inner depth: 8.7 mm {0.34 in} or more
12. After installing the new clip onto the drive shaft,
insert the drive shaft into the differential. (See 03-
13-22 REAR DRIVE SHAFT REMOVAL/
49 G030 796
INSTALLATION.) 49 G030 797
13. Verify that the drive shaft cannot be pulled out.
ac9uuw00002077
14. Install in the reverse order of removal.
15. Add the specified differential oil.
16. After adding the oil, perform an oil level inspection. (See 03-14-2 DIFFERENTIAL OIL INSPECTION.)
17. Install a new washer and the oil filler plug, and tighten.

Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7 ft·lbf}

18. Inspect the rear wheel alignment and adjust it if necessary. (See 02-11-5 REAR WHEEL ALIGNMENT [AWD].)
End Of Sie
OIL SEAL (COMPANION FLANGE) REPLACEMENT
id031400800800
1. Drain the differential oil into a container.
2. Remove the presilencer installation nuts. (Middle pipe side) (See 01-15-1 EXHAUST SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
3. Disconnect the hanger rubber as shown in the HANGER RUBBER
figure.
4. Suspend the presilencer using a cable. PRESILENCER
5. Remove the presilencer insulator. INSULATOR
6. Remove the propeller shaft. (See 03-15-2
PROPELLER SHAFT REMOVAL/
INSTALLATION.)

PRESILENCER

8—10 N·m {82—101 kgf·m, 71—88 in·lbf}

ac9uuw00002494

7. Remove the locknut using the SST and a pipe.

8. Support the differential using a jack.
49 S120 710

PIPE

ac9uuw00001476

03-14–4
1890-1U-06H(03-14).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
9. After removing the front side of the differential
mount, gradually lower the jack and tilt the front
side of the differential downward.

DIFFERENTIAL

JACK
ac9uuw00001477
03-14
10. Pull the companion flange off using the SST.
11. Remove the oil seal from the differential carrier 49 0839 425C
using a screwdriver or similar tool.
12. Apply differential oil to the new oil seal lip.

ac9uuw00001478

13. Install the new oil seal to the differential carrier

using the SST.
49 W011 102
Substitution SST
• 49 W011 102
Outer diameter: 66 mm {2.60 in} or more
Inner diameter: 54—60 mm {2.13—2.36 in} or
more
Inner depth: 17.5 mm {0.69 in} or more
14. Install the companion flange to the drive pinion.
15. Jack up the differential and install the front side of
the differential mount.
ac9uuw00001479
Tightening torque
63—85 N·m {6.5—8.6 kgf·m, 47—62 ft·lbf}

16. Install the washer and a new locknut.

17. Tighten the locknut to the specified torque using
the SST and a pipe.

Tightening torque 49 S120 710

167—226 N·m {17.1—23.0 kgf·m, 124—166
ft·lbf}

18. Install the propeller shaft. (See 03-15-2

PROPELLER SHAFT REMOVAL/ PIPE
INSTALLATION.)
19. Add the specified differential oil from the filler
plug. (See 03-14-3 DIFFERENTIAL OIL
ac9uuw00001480
REPLACEMENT.)
End Of Sie

03-14–5
1890-1U-06H(03-14).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
REAR DIFFERENTIAL REMOVAL/INSTALLATION
id031400800400
1. Drain the rear differential oil into a container.
2. Remove the under guard (LH). (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID
VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the presilencer. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the presilencer insulator. (See 07-11-17 REFRIGERANT LINE REMOVAL/INSTALLATION.)
5. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Add the specified rear differential oil. (See 03-14-3 DIFFERENTIAL OIL REPLACEMENT.)
9. Inspect the rear wheel alignment and adjust it if necessary. (See 02-11-5 REAR WHEEL ALIGNMENT [AWD].)

43—61
{4.4—6.2,
8 32—44}

10

SEALANT

6 63—85
22.6—26.4 {2.31—2.69, 16.7—19.4} {6.5—8.6,
47—62}

63—85 {6.5—8.6, 47—62} 3

A 1
2 R
4 235—275
{24.0—28.0,
174—202}

7
5 N·m {kgf·m, ft·lbf}
63—85 {6.5—8.6, 47—62}
ac9uuw00001445

1 Locknut 6 Nut
(See 03-14-7 Locknut Removal Note.) 7 Rear differential component
(See 03-12-5 WHEEL HUB COMPONENT (See 03-14-7 Rear Differential Component Removal
REMOVAL/INSTALLATION [AWD].) Note.)
2 Differential oil temperature sensor connector (See 03-14-8 Rear Differential Component
3 AWD solenoid connector installation Note.)
4 Front differential mounting rubber (RH) 8 Rear differential mounting rubber
(See 03-14-7 Rear Differential Component Removal 9 Coupling component
Note.) (See 03-19-4 COUPLING COMPONENT
5 Front differential mounting rubber (LH) REMOVAL/INSTALLATION)
(See 03-14-7 Rear Differential Component Removal 10 Rear differential
Note.)

03-14–6
1890-1U-06H(03-14).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Locknut Removal Note
1. Lock the hub by applying the brakes.
2. Knock the crimped portion of the locknut outward
using a small chisel and a hammer.
3. Loosen the locknut.
4. Temporarily tighten the locknut.

Caution
• Do not remove the locknut when lowering
the rear differential. Otherwise, the rear
drive shaft could fall and cause injury, or
damage the part.
03-14
ampjjw00004289

Rear Differential Component Removal Note

1. Detach clips as shown in the figure.

ac9uuw00001446

2. Position the SST on the driveshaft and secure the

SST with tape as shown in the figure. 49 B025 010

Caution
• Always secure the SST using tape
because the SST may fall off during the
operation and cause injury.

TAPE TAPE

ac9uuw00001531

3. Disconnect the rear drive shaft from the rear

differential side using the SST and two bars. 49 B025 010

BAR

ac9uuw00001532

03-14–7
1890-1U-06H(03-14).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
4. Support the rear differential using a jack.

Caution
• When lowering the rear differential, be
careful not to damage the rear differential
oil seal, rear drive shaft, and surrounding
parts.

JACK

ac9uuw00001448

5. Remove the rear drive shaft from the rear

differential while lowering the rear differential
gradually.

JACK

ac9uuw00001449

6. Suspend the drive shaft using a cable.

CABLE
CABLE
ac9uuw00001723

Rear Differential Component installation Note

Caution
• When raising the rear differential, be careful not to damage the rear differential oil seal, rear drive
shaft, and surrounding parts.

1. Install the rear drive shaft to the rear differential

while raising the rear differential gradually.
2. Jack up the rear drive shaft until it is horizontal
and engage the rear drive shaft (differential side)
and rear differential by tapping the wheel side.
End Of Sie

JACK

ac9uuw00001449

03-14–8
1890-1U-06H(03-14).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
REAR DIFFERENTIAL DISASSEMBLY
id031400800500

Warning
• The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a
tilted condition, the self-lock mechanism could become inoperative. If the rear differential
unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted
condition. When turning the rear differential, grasp the rotation handle firmly.
1. Disassemble in the order indicated in the table.

7 3 2
10 6 03-14
SST
13 14
11
19
15

5 18 3
23
SST

17
22
21 25 23
21 SST 5
20
1 24 6

22 4
SST
24

16
15
12
8 9
SST
acxuuw00001405
.

1 Differential oil temperature sensor 13 Bearing inner race (rear bearing)

2 Rear cover (See 03-14-11 Bearing Inner Race (Rear Bearing)
(See 03-14-10 Rear Cover Disassembly Note) Disassembly Note)
3 Bearing cap 14 Spacer
(See 03-14-10 Bearing Cap Disassembly Note) 15 Bearing outer race
4 Rear differential component (See 03-14-11 Bearing Outer Race Disassembly
(See 03-14-10 Rear Differential Component Note)
Disassembly Note) 16 Differential carrier
5 Side bearing outer race 17 Ring gear
6 Adjusting shim (See 03-14-12 Ring Gear Disassembly Note)
7 Spacer 18 Knock pin
8 Locknut 19 Pinion shaft
(See 03-14-11 Locknut Disassembly Note) 20 Pinion gear
9 Washer 21 Side gear
10 Drive pinion 22 Thrust washer
(See 03-14-11 Drive Pinion Disassembly Note) 23 Side bearing inner race
11 Collapsible spacer (See 03-14-12 Side Bearing Inner Race
12 Bearing inner race (front bearing) Disassembly Note)
24 Oil seal
25 Gear case

03-14–9
1890-1U-06H(03-14).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Rear Cover Disassembly Note
1. Install the SSTs to the engine stand.

49 L027 0A2

49 0107 680A

acxuuw00001406

2. Install the rear differential to the SSTs.

3. Remove the rear cover using an oil seal cutter.

49 0107 680A

49 L027 0A2

acxuuw00001407

Bearing Cap Disassembly Note

1. Place alignment marks on the bearing cap and
carrier.
MARK

acxuuw00001408

Rear Differential Component Disassembly Note

1. Remove the rear differential component using the
SSTs.
2. Mark or otherwise distinguish between the 49 T032 317
removed left and right adjusting shims, spacers
and side bearing outer races so that they are not
mixed up at the time of reassembly. 49 T032 316

49 L027 004

acxuuw00001409

03-14–10
1890-1U-06H(03-14).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Locknut Disassembly Note
1. Remove the locknut using the SSTs.

49 L027 006

49 L027 007

acxuuw00001410 03-14

Drive Pinion Disassembly Note

1. Remove the drive pinion by lightly tapping with a
copper hammer.

acxuuw00001411

Bearing Inner Race (Rear Bearing) Disassembly Note

1. Remove the bearing inner races (rear bearing)
using the SST and a press.

49 H027 002

acxuuw00001412

Bearing Outer Race Disassembly Note

1. Remove the bearing outer races using the 2
grooves in the carrier and alternately tapping the
sides of the races with a brass bar.

acxuuw00001413

03-14–11
1890-1U-06H(03-14).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Ring Gear Disassembly Note
1. Secure the gear case in a vice and remove the
bolts.
2. Lightly tap around the ring gear using a plastic
hammer to remove the ring gear from the gear
case.

acxuuw00001414

Side Bearing Inner Race Disassembly Note

Note
• Mark or otherwise distinguish between the left and right side bearings so that they are not mixed up at the
time of reassembly.

1. Remove the side bearing inner races from the

gear case using the SST and a press.
End Of Sie

49 0839 425C

acxuuw00001415

REAR DIFFERENTIAL ASSEMBLY

id031400800600

Warning
• The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a
tilted condition, the self-lock mechanism could become inoperative. If the rear differential
unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted
condition. When turning the rear differential, grasp the rotation handle firmly.

Note
• Clean away the old sealant before applying the new sealant.
• Install the rear cover within 10 minutes after applying sealant.
• Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified
oil.

1. Assemble in the order indicated in the table.

03-14–12
1890-1U-06H(03-14).fm 13 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL

38—51
SEALANT 15.7—22.6
{3.9—6.2, 24 {1.6—2.3,
28.1—37.6} 11.6—16.6}

23
R
SST 38—51
SST 15 {3.9—6.2,
12 11 SEALANT 28.1—37.6}
R 14 8 68.6—83.3
19 {9.0—8.49,
R SST 10 22 50.6—61.4}
6 03-14
20 7 23
2
SST
12.7—17.3 R
{1.3—1.7,
2 SST
9.4—12.7}
SST
26 20
25 OIL
3
1
4 4
5

R
3 18
9 26 21
SST
10 SST R OIL

13 R
17
16
R SST
240—755
{24.5—76.9, 177—556}
N·m {kgf·m, ft·lbf}
acxuuw00002352

1 Gear case 13 Bearing inner race (front bearing)

2 Side bearing inner race (See 03-14-16 Spacer, Bearing Inner Race
(See 03-14-14 Side Bearing Inner Race Assembly Assembly Note)
Note) 14 Collapsible spacer
3 Thrust washer 15 Drive pinion
(See 03-14-14 Thrust washer Assembly Note) 16 Locknut
4 Side gear (See 03-14-18 Locknut Assembly Note)
5 Pinion gear 17 Washer
6 Pinion shaft 18 Adjusting shim (L)
7 Knock pin (See 03-14-18 Adjusting Shim Assembly Note)
8 Ring gear 19 Spacer
(See 03-14-15 Ring Gear Assembly Note) 20 Side bearing outer race
9 Differential carrier 21 Rear differential component
10 Bearing outer race 22 Adjusting shim (R)
(See 03-14-15 Bearing Outer Race Assembly Note) 23 Bearing cap
11 Spacer (See 03-14-20 Bearing Cap Assembly Note)
(See 03-14-16 Spacer, Bearing Inner Race 24 Rear cover
Assembly Note) (See 03-14-21 Rear Cover Assembly Note)
12 Bearing inner race (rear bearing) 25 Differential oil temperature sensor
(See 03-14-16 Spacer, Bearing Inner Race
Assembly Note) 26 Oil seal
(See 03-14-21 Oil Seal Assembly Note)

03-14–13
1890-1U-06H(03-14).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Side Bearing Inner Race Assembly Note

Caution
• Do not mix up the left and right side bearing inner races.

1. Press the side bearing inner races into the gear

case using the SSTs. 49 F401 331
Substitution SST
• 49 G030 338
Outer diameter: 43—45 mm {1.70—1.77 in}
Inner diameter: 41 mm {1.61 in} or more
Inner depth: 3 mm {0.12 in} or more 49 G030 338

acxuuw00001417

Thrust washer Assembly Note

1. Assemble the side gears, thrust washers and pinion gears to the gear case, then assemble the knock pin.
2. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case.
3. Set a dial gauge to the pinion gear as indicated in
the figure.
4. Secure one of the side gears.

acxuuw00001418

5. Move the pinion gear and measure the backlash at the end of the pinion gear.
• If the backlash exceeds the standard, use the thrust washers to adjust.

Rear differential backlash of pinion gear and side gear

0.1 mm {0.004 in} or less

Thrust washer thickness

Identification mark Thickness
0 2.0 mm {0.079 in}
1 2.1 mm {0.083 in}
2 2.2 mm {0.086 in}
05 2.05 mm {0.081 in}
15 2.15 mm {0.084 in}

03-14–14
1890-1U-06H(03-14).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Ring Gear Assembly Note

Caution
• The differential gear and ring gear could be damaged if the ring gear is installed with old thread-
locking compound remaining on the bolt threads. Before installing the ring gear, completely
remove the old thread-locking compound from the bolt threads.

1. Apply a small amount of thread-locking

compound to each of points A on the back of the
A
ring gear, and bolt thread areas B (around the
entire ring).
B
Application amount
03-14
Back of ring gear:
Approx. 0.4 ml {0.4 cc, 0.02 cu in}
Ring gear bolt thread points:
Approx. 0.4 ml {0.4 cc, 0.02 cu in}
(0.04 ml {0.04 cc, 0.002 cu in} to each
point)
acxuuw00001419

2. Align the marks placed on the ring gear case at

the time of disassembly and tighten the bolts in
diagonal order.

Tightening torque
68.6—83.3 N·m {7.00—8.49 kgf·m, 50.6—61.4
ft·lbf}

acxuuw00001420

Bearing Outer Race Assembly Note

1. Press in the bearing outer race using the SSTs
and a press.
Substitution SST 49 M005 797
• 49 F027 007
Outer diameter: 70.8—71.0 mm {2.78—2.79
in}
Plate thickness: 1 mm {0.04 in} or more 49 F027 007
• 49 F027 004
Outer diameter: 78.5—79.0 mm {3.10—3.11
in}
Plate thickness: 1 mm {0.04 in} or more 49 F027 004
acxuuw00001421

03-14–15
1890-1U-06H(03-14).fm 16 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Spacer, Bearing Inner Race Assembly Note
Pinion height adjustment

Note
• Use the same spacer.
• Install the spacer with the chamfer on the SST side.

1. Assemble the spacer, the bearing inner race (rear

bearing), and the SST O-ring to the SST (49 8531
565) as shown in the figure. 49 0305 555
2. Insert the set assembled in Step 1 to the
differential gear from the rear.
3. Assemble the bearing inner race (front bearing),
SST (49 G027 005), companion flange, washer,
and locknut from the front of the differential gear. 49 8531 565
4. Tighten the locknut to the extent that the SST (49
8531 565) can be turned by hand.
5. Place the SST (49 0305 555) on top of the SST
(49 8531 565). 49 8531 568

49 G027 005

49 G032 347

acxuuw00001422

6. Place the SST on the surface plate and set the

dial indicator to zero.

49 0727 570

acxuuw00001423

7. Set the SST as shown in the figure.

8. Place the measuring probe of the dial indicator so
that it contacts the place where the side bearing is
installed in the carrier. Then measure the left and
right side of the lower position. 49 0727 570

acxuuw00001424

03-14–16
1890-1U-06H(03-14).fm 17 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
9. Add the two (left and right) values obtained by the
measurements taken in Step 8 and then divide
the total by 2. From this result, subtract the result
obtained by dividing the number inscribed on the
end surface of the drive pinion by 100. (If there is
no figure inscribed, use 0.) This is the pinion
height adjustment value.

Rear differential pinion height

–0.032—0.032 mm {–0.0012—0.0012 in}

Note
• For example, the measured results obtained
03-14
at Step 8 and 9 are 0.06 mm {0.003 in} and
0.04 mm {0.002 in}, and the figure inscribed
on the end of the drive pinion is 2:
((0.06 mm {0.003 in}+ 0.04 mm {0.002 in}) /
2) – (2/100) = 0.03 mm {0.001 in} (pinion
height adjustment value)
Replace with a spacer 0.03 mm {0.001 in}
thicker than the currently used one. Spacer
thickness is set at 0.015 mm {0.0006 in}
increments, therefore select the closest
spacer thickness and assemble. acxuuw00001425
• Install the spacer with the chamfer on the
SST side.

Spacer thickness
Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in})
08 3.08 {0.1213} 29 3.29 {0.1295}
09 3.095 {0.1219} 30 3.305 {0.1301}
11 3.11 {0.1224} 32 3.32 {0.1307}
12 3.125 {0.1230} 33 3.335 {0.1313}
14 3.14 {0.1236} 35 3.35 {0.1319}
15 3.155 {0.1242} 36 3.365 {0.1325}
17 3.17 {0.1248} 38 3.38 {0.1331}
18 3.185 {0.1254} 39 3.395 {0.1337}
20 3.20 {0.1260} 41 3.41 {0.1343}
21 3.215 {0.1266} 42 3.425 {0.1348}
23 3.23 {0.1272} 44 3.44 {0.1354}
24 3.245 {0.1278} 45 3.455 {0.1360}
26 3.26 {0.1283} 47 3.47 {0.1366}
27 3.275 {0.1289} — —

10. Assemble the spacer selected for the pinion height adjustment to the drive pinion.
11. Press the bearing inner race (rear bearing) into
the drive pinion using the SSTs and a press.
Substitution SST 49 F401 331
• 49 V001 525
Outer diameter: 37.2—50.3 mm {1.47—1.98
in}
Inner diameter: 35.2 mm {1.39 in} or more 49 V001 525
Inner depth: 134.3 mm {5.29 in} or more
Plate thickness: 1 mm {0.04 in} or more

acxuuw00001426

03-14–17
1890-1U-06H(03-14).fm 18 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Locknut Assembly Note
Drive pinion preload adjustment
1. Apply differential oil to a new locknut.
2. Assemble a new collapsible spacer, bearing inner race (front bearing), spacer and locknut to the drive pinion,
and temporarily tighten the locknut.
3. Turn the serrated part of the drive pinion by hand to seat the bearing.
4. Tighten the locknut temporarily tightened in Step
1 from the lower limit of the specified tightening
torque using the SSTs, and make this the 49 L027 006
specified preload.
• If the specified preload cannot be obtained
within the specified tightening torque, replace
the collapsible spacer and inspect again.
49 L027 007
Tightening torque
240—755 N·m {24.5—76.9 kgf·m, 177—556
ft·lbf}
acxuuw00001427
Rear differential drive pinion preload
1.3—1.8 N·m {13.3—18.2 kgf·cm, 11.5—15.9
in·lbf}

5. Crimp the locknut using a chisel and hammer.

1.0 mm {0.04 in}

LOCKNUT

acxuuw00001428

Adjusting Shim Assembly Note

1. Assemble the differential carrier to the SSTs.
2. Assemble the spacer to the differential carrier.
3. Stack the side bearing outer race and gear case
component on the surface plate as indicated in
the figure, and measure the height using a caliper
and a ruler. This is value A.

acxuuw00001429

03-14–18
1890-1U-06H(03-14).fm 19 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
4. Measure the width of the installed differential in
the differential carrier with the spacer installed.
This is value B. SPACER
5. The combined thickness of the left and right
adjusting shims is obtained by the following
formula.
C1 = B – A + 0.15 mm {0.006 in} B
C2 = B – A + 0.44 mm {0.017 in}
6. If the combined thickness of the previously
installed adjusting shims is between C1 and C2,
use the shims as they are.
7. If the combined thickness of the previously acxuuw00001430
installed adjusting shims is not between C1 and 03-14
C2, or if the adjusting shims have to be replaced,
select two appropriate adjusting shims from the table below.
Adjusting shim thickness
Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in})
350 3.50 {0.137} 410 4.10 {0.161}
355 3.55 {0.139} 415 4.15 {0.163}
360 3.60 {0.141} 420 4.20 {0.165}
365 3.65 {0.143} 425 4.25 {0.167}
370 3.70 {0.145} 430 4.30 {0.169}
375 3.75 {0.147} 435 4.35 {0.171}
380 3.80 {0.149} 440 4.40 {0.173}
385 3.85 {0.151} 445 4.45 {0.175}
390 3.90 {0.153} 450 4.50 {0.177}
395 3.95 {0.155} 455 4.55 {0.179}
400 4.00 {0.157} 460 4.60 {0.181}
405 4.05 {0.159} — —

Caution
• If adjusting shims are to be reused, do not mix up the left and right shims.
• Do not mix up the left and right side bearing outer races and spacers.

8. Assemble the selected adjusting shims to the differential carrier ring gear side, and the spacer to the opposite
side.
9. Assemble the differential and bearing outer race to the differential carrier.
10. Tap the selected adjusting shim between the
spacer and the bearing race with a plastic
hammer as shown in the figure.
11. Align the bearing cap alignment marks to
assemble the bearing cap, and temporarily
tighten the bolts.
12. Place the dial indicator so that the measuring
probe contacts the top surface of one of the ring
gear teeth perpendicularly.
13. Secure the drive pinion and measure the
backlash from when the ring gear moved.
Rear differential backlash of drive pinion and acxuuw00001431
ring gear
Standard: 0.09—0.11 mm {0.003—0.004 in}
Minimum value: 0.05 mm {0.002 in}
Note
• Measure the backlash at 4 locations around the ring gear. Make sure one of the 4 locations is within
specification, and the minimum value for the 4 locations is 0.5 mm {0.002 in} or less.
14. If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.
Note
• When moving the gear case component in the axial direction, replace the adjusting shims. If the adjusting
shim on the right side is replaced with one that is 0.05 mm {0.002 in} thicker, replace the one on the left
with one that is 0.05 mm {0.002 in} thinner.

03-14–19
1890-1U-06H(03-14).fm 20 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Bearing Cap Assembly Note
1. Align the bearing cap alignment marks to assemble the bearing cap.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 28.1—37.0 ft·lbf}

2. Inspect the drive pinion and ring gear teeth

contact points.
MARK

acxuuw00001432

(1) Coat both surfaces of the ring gear uniformly

with a thin red lead coating.
(2) While rotating the ring gear back and forth by
hand, rotate the drive pinion several times and
inspect the tooth contact.
(3) Inspect the tooth contacts in four locations
around the ring gear, and check that the tooth
contacts showing the red lead coating are the
same as the pattern indicated in the figure.
• If the tooth contact is good, wipe off the
red lead coating.
• If it is not good, adjust the pinion height,
acxuuw00001433
then adjust the backlash.
(4) If toe and flank contact appears as shown in
the figure, replace the spacer with a thinner
one, and move the drive pinion outward.

acxuuw00001434

(5) If heel and face contact appears as indicated

in the figure, replace the spacer with a thicker
one and move the drive the pinion inward.

acxuuw00001435

03-14–20
1890-1U-06H(03-14).fm 21 ページ ２００６年１２月１９日　火曜日　午前１１時２３分

DIFFERENTIAL
Rear Cover Assembly Note

Caution
• Clean away the old sealant before applying the new sealant.
• Install the rear differential within 10 minutes after applying sealant.
• Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oil.

1. Clean the alignment surface of the carrier and rear cover, and apply a thin coat of sealant.
2. Install the rear cover.

Tightening torque
15.7—22.6 N·m {1.6—2.3 kgf·m, 11.6—16.6 ft·lbf}
03-14
Oil Seal Assembly Note
1. Apply differential oil to the new oil seal lip.
2. Assemble the oil seal using the SSTs.
Substitution SST
• 49 G030 796 49 G030 797
Outer diameter: 56—60 mm {2.21—2.36 in}
Inner diameter: 49.8 mm {1.96 in} or more
Inner depth: 8.7 mm {0.34 in} or more 49 G030 796
End Of Sie

acxuuw00001436

03-14–21
1890-1U-06H(03-15).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時２５分

PROPELLER SHAFT
03-15 PROPELLER SHAFT
PROPELLER SHAFT Propeller Shaft
LOCATION INDEX. . . . . . . . . . . . . . . . . 03-15–1 Runout Inspection . . . . . . . . . . . . . . . . 03-15–2
PROPELLER SHAFT ON-VEHICLE PROPELLER SHAFT
INSPECTION . . . . . . . . . . . . . . . . . . . . . 03-15–2 REMOVAL/INSTALLATION . . . . . . . . . . 03-15–2
Joint Area Excessive Bolt and Nut Removal Note. . . . . . . . . . 03-15–3
Play Inspection. . . . . . . . . . . . . . . . . . 03-15–2 Propeller Shaft Installation Note . . . . . . 03-15–4
PROPELLER SHAFT
INSPECTION . . . . . . . . . . . . . . . . . . . . . 03-15–4

End of Toc
03-15
PROPELLER SHAFT LOCATION INDEX
WM: PROPELLER SHAFT

id031500800100

ac9uuw00001376

1 Propeller shaft
(See 03-15-2 PROPELLER SHAFT ON-VEHICLE
INSPECTION.)
(See 03-15-2 PROPELLER SHAFT REMOVAL/
INSTALLATION.)
(See 03-15-4 PROPELLER SHAFT INSPECTION.)

End Of Sie

03-15–1
1890-1U-06H(03-15).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時２５分

PROPELLER SHAFT
PROPELLER SHAFT ON-VEHICLE INSPECTION
id031500800200
Joint Area Excessive Play Inspection
1. Shake the universal joint by hand and verify that
there is no excessive play.
2. If there is any excessive play, replace the
propeller shaft. (See 03-15-2 PROPELLER
SHAFT REMOVAL/INSTALLATION.)

ac9uuw00001380

Propeller Shaft Runout Inspection

Caution
• Do not rotate the propeller shaft using engine force when inspecting.

1. Shift to neutral position and release the parking brake.

2. Rotate the rear wheel by hand and inspect the
propeller shaft runout at the three locations
shown in the figure.
• If it exceeds the standard specification,
replace the propeller shaft.

Standard propeller shaft runout (on-vehicle)

0.8 mm {0.031 in}

End Of Sie

ac9uuw00001377

PROPELLER SHAFT REMOVAL/INSTALLATION

id031500800300
1. Remove the presilencer installation nuts. (Middle pipe side) (See 01-15-1 EXHAUST SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
2. Disconnect the hanger rubber as shown in the HANGER RUBBER
figure.
3. Suspend the presilencer using a cable. PRESILENCER
4. Remove the presilencer insulator. INSULATOR
5. Remove in the order indicated in the figure.
6. Install in the reverse order of removal.

PRESILENCER

8—10 N·m {82—101 kgf·m, 71—88 in·lbf}

ac9uuw00002494

03-15–2
1890-1U-06H(03-15).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時２５分

PROPELLER SHAFT

49.0—58.0 3
{5.0—5.9,
37—42}

6
5
03-15
8

7 49.0—58.0 5
{5.0—5.9,
37—42}
4

37.3—52.0
{3.9—5.3,
28—38}

2
1
21.6—30.4
{2.3—3.0,
16—22} N·m {kgf·m, ft·lbf}
ac9uuw00001913

Under guard (LH) 4 Bolt

(See 01-16-5 CHARCOAL CANISTER, CANISTER 5 Bush
1 VENT (CV) SOLENOID VALVE, AIR FILTER
COMPONENT REMOVAL/INSTALLATION [MZI- 6 Spacer
3.5].) Bolt
7
2 Member (See 03-15-3 Bolt and Nut Removal Note.)
Nut Propeller shaft
3 8
(See 03-15-3 Bolt and Nut Removal Note.) (See03-15-4 Propeller Shaft Installation Note.)

Bolt and Nut Removal Note

Caution
• Do not mark with a punch to prevent imbalance.

1. Before removing the nut, place alignment marks FRONT REAR

on the companion flange (front) and constant
velocity joint, and on the companion flange (rear)
and yoke.

acxuuw00001383

03-15–3
1890-1U-06H(03-15).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時２５分

PROPELLER SHAFT
Propeller Shaft Installation Note
1. Align the alignment marks and install the propeller
FRONT REAR
shaft.

acxuuw00001383

2. When installing a new propeller shaft, align the

rear differential companion flange mark with the
tag on the propeller shaft so that they are at the
nearest position, and assemble.
3. Perform a road test and verify that there is no
abnormal vibration or noise.
End Of Sie

MARKING

ac9uuw00001399

PROPELLER SHAFT INSPECTION

id031500800500
1. Measure the propeller shaft center runout using
the dial gauge.
• If it exceeds the maximum specification,
replace the propeller shaft as a single
component.

Propeller shaft maximum runout

0.8 mm {0.031 in}

ac9uuw00001378

2. Inspect the play and rotation of the joint by turning

the universal joint in the directions shown by the
arrows.
• If it is not within the specification, replace the
propeller shaft.

Propeller shaft starting torque

0.29—1.47 N·m {3.0—14.9 kgf·cm, 2.6—13.0
in·lbf}

End Of Sie
ac9uuw00001379

03-15–4
1890-1U-06H(03-16).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時２７分

TRANSFER
03-16 TRANSFER
TRANSFER LOCATION INDEX . . . . . . . 03-16–1 TRANSFER
TRANSFER OIL SEAL REMOVAL/INSTALLATION . . . . . . . . . . 03-16–4
REPLACEMENT . . . . . . . . . . . . . . . . . . 03-16–2 Transfer Removal Note . . . . . . . . . . . . . 03-16–5
Right Side . . . . . . . . . . . . . . . . . . . . . . 03-16–2 Transfer Installation Note. . . . . . . . . . . . 03-16–6
Left Side . . . . . . . . . . . . . . . . . . . . . . . . 03-16–3 Transfer Bracket
Installation Note . . . . . . . . . . . . . . . . . 03-16–6

End of Toc
TRANSFER LOCATION INDEX
WM: TRANSFER

id031600800100
03-16

2
ac9uuw00001700

1 Transfer oil seal 2 Transfer

(See 03-16-2 TRANSFER OIL SEAL (See 03-16-4 TRANSFER REMOVAL/
REPLACEMENT.) INSTALLATION.)

End Of Sie

03-16–1
1890-1U-06H(03-16).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時２７分

TRANSFER
TRANSFER OIL SEAL REPLACEMENT
id031600800400
Right Side
1. Remove the middle pipe. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the front pipe. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the joint shaft. (See 03-13-5 JOINT SHAFT REMOVAL/INSTALLATION [AWD].)
4. Using the SST, remove the deflector.

49 S231 660
ac9uuw00001694

5. Using the SST, remove the oil seal.

49 S231 660
ac9uuw00001695

6. Mark the SST at position 18 mm {0.71 in} from

the end. 49 B032 334

MARKING

18 mm {0.71 in}

ac9uuw00002023

7. Using the SST and a hammer, tap new oil seal.

Substitution SST MARKING
• 49 B032 334
Outer diameter: 38—42 mm {1.5—1.6 in} 18 mm {0.71 in}
Plate thickness: 2 mm {0.08 in} or more
8. Warm up the new deflector using a hot air blower.

49 B032 334

ac9uuw00001696

03-16–2
1890-1U-06H(03-16).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時２７分

TRANSFER
9. Within 10 s after warming up the deflector, install
the new deflector using the SST.
Substitution SST 49 B032 334
• 49 B032 334
Outer diameter: 38—42 mm {1.5—1.6 in}
Plate thickness: 2 mm {0.08 in} or more
10. Install the joint shaft. (See 03-13-5 JOINT SHAFT
REMOVAL/INSTALLATION [AWD].)
11. Install the front pipe. (See 01-15-1 EXHAUST
SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
12. Install the middle pipe. (See 01-15-1 EXHAUST
SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
ac9uuw00001697
13. Inspect for leakage of transfer oil.
03-16
Left Side
1. Remove the transfer. (See 03-16-4 TRANSFER REMOVAL/INSTALLATION.)
2. Remove the oil seal using a screwdriver.

ac9uuw00001698

3. Install the new oil seal.

4. Install the transfer. (See 03-16-4 TRANSFER
REMOVAL/INSTALLATION.)
5. Inspect for leakage of transfer oil.
End Of Sie

ac9uuw00001699

03-16–3
1890-1U-06H(03-16).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時２７分

TRANSFER
TRANSFER REMOVAL/INSTALLATION
id031600800600
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Middle pipe (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
(2) Front pipe (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
(3) Stabilizer control link (See 02-13-11 FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
(4) Tie-rod end ball joint (right side) (See 02-13-11 FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
(5) Front lower arm ball joint (right side) (See 02-13-11 FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
(6) Front drive shaft (right side) (See 03-13-14 FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
(7) Joint shaft (See 03-13-5 JOINT SHAFT REMOVAL/INSTALLATION [AWD].)
3. Disconnect the propeller shaft from the transfer side. (See 03-15-2 PROPELLER SHAFT REMOVAL/
INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Warm up the engine and transaxle, inspect for oil leakage, and inspect the transfer operation.

90—100
{9.2—10.1,
66.4—73.7}

90—100
{9.2—10.1,
66.4—73.7}

42—62
{4.3—6.3,
31—45}

2 1

42—62
{4.3—6.3,
31—45}
N·m {kgf·m, ft·lbf}

ac9uuw00001688

1 Transfer bracket 2 Transfer

(See 03-16-5 Transfer Removal Note.)
(See 03-16-6 Transfer Installation Note.)

03-16–4
1890-1U-06H(03-16).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時２７分

TRANSFER
Transfer Removal Note
1. Disconnect the front stabilizer control link, and
rotate the stabilizer to the front to secure a space
from the side. FRONT
STABILIZER

ac9uuw00001689 03-16
2. Remove the No.1 engine mount bolt and nut.
3. Remove the transfer installation bolts.
BOLT AND NUT

ac9uuw00001690

4. Push the engine forward so that the front side of

the transfer faces downward, then remove the
transfer.

ENGINE

TRANSFER

ac9uuw00001691

03-16–5
1890-1U-06H(03-16).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時２７分

TRANSFER
Transfer Installation Note
1. Push the engine forward so that the front side of
the transfer faces downward, then install the
transfer.
2. Install the transfer installation bolts.

Tightening torque
90—100 N·m {9.2—10.1 kgf·m, 66.4—73.7
ft·lbf} ENGINE

TRANSFER

ac9uuw00001692

3. Install the No.1 engine mount bolt and nut.

Tightening torque BOLT AND NUT

85.3—116.6 N·m {8.70—11.88 kgf·m, 63.0—
85.9 ft·lbf}

ac9uuw00001690

4. Rotate the front stabilizer to the rear to set it in its

original position.
FRONT
STABILIZER

ac9uuw00001693

Transfer Bracket Installation Note

1. Install the transfer bracket to the transfer, then A D
temporarily tighten bolt C.
2. Temporarily tighten bolt A and B. A
3. Tighten bolt A, B and C in the order of C→A→B. D
B

Tightening torque
Bolt A, B, C: 42—62 N·m {4.3—6.3 kgf·m, D
31—45 ft·lbf}
C
4. Tighten bolt D.

Tightening torque
ac9uuw00002213
Bolt D: 42—62 N·m {4.3—6.3 kgf·m, 31—45
ft·lbf}

End Of Sie

03-16–6
1890-1U-06H(03-19).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

03-19 ALL WHEEL DRIVE (AWD)
ELECTRONIC AWD CONTROL Companion Flange
SYSTEM LOCATION INDEX. . . . . . . . . 03-19–1 Disassembly Note . . . . . . . . . . . . . . . . 03-19–7
AWD CONTROL MODULE Output Shaft Disassembly Note . . . . . . 03-19–8
INSPECTION . . . . . . . . . . . . . . . . . . . . . 03-19–2 Bearing Disassembly Note . . . . . . . . . . 03-19–8
Terminal Voltage List COUPLING COMPONENT
(Reference) . . . . . . . . . . . . . . . . . . . . 03-19–2 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 03-19–9
AWD CONTROL MODULE Output Shaft Assembly Note . . . . . . . . . 03-19–10
REMOVAL/INSTALLATION. . . . . . . . . . 03-19–3 Bearing Assembly Note. . . . . . . . . . . . . 03-19–10
AWD CM Removal Note. . . . . . . . . . . . 03-19–3 Coupling Case Assembly Note . . . . . . . 03-19–10
COUPLING COMPONENT Oil Seal Assembly Note . . . . . . . . . . . . 03-19–10
REMOVAL/INSTALLATION. . . . . . . . . . 03-19–4 Companion Flange 03-19
Front Differential Mounting Assembly Note . . . . . . . . . . . . . . . . . . 03-19–11
Rubber Removal Note . . . . . . . . . . . . 03-19–5 Locknut Assembly Note. . . . . . . . . . . . . 03-19–11
Coupling Component DIFFERENTIAL OIL TEMPERATURE
Removal Note . . . . . . . . . . . . . . . . . . 03-19–5 SENSOR INSPECTION . . . . . . . . . . . . . 03-19–11
Coupling Component DIFFERENTIAL OIL TEMPERATURE
Installation Note . . . . . . . . . . . . . . . . . 03-19–5 SENSOR
COUPLING COMPONENT REMOVAL/INSTALLATION . . . . . . . . . . 03-19–12
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 03-19–6 AWD SOLENOID INSPECTION . . . . . . . . 03-19–12
Locknut Disassembly Note. . . . . . . . . . 03-19–7

End of Toc
ELECTRONIC AWD CONTROL SYSTEM LOCATION INDEX
WM: ELECTRONIC 4WD CONTROL SYSTEM

id031900800100

2 4

ac9uuw00001405

1 Differential oil temperature sensor 3 AWD control module

(See 03-19-11 DIFFERENTIAL OIL (See 03-19-2 AWD CONTROL MODULE
TEMPERATURE SENSOR INSPECTION) INSPECTION)
(See 03-19-12 DIFFERENTIAL OIL (See 03-19-3 AWD CONTROL MODULE
TEMPERATURE SENSOR REMOVAL/ REMOVAL/INSTALLATION)
INSTALLATION) 4 Coupling component
2 AWD solenoid (See 03-19-4 COUPLING COMPONENT
(See 03-19-12 AWD SOLENOID INSPECTION) REMOVAL/INSTALLATION)
(See 03-19-6 COUPLING COMPONENT
DISASSEMBLY)
(See 03-19-9 COUPLING COMPONENT
ASSEMBLY)

End Of Sie
WM: 4WD CONTROL MODULE

03-19–1
1890-1U-06H(03-19).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

AWD CONTROL MODULE INSPECTION
id031900800200

Note
• AWD CM terminal voltage can vary depending on measuring conditions and vehicle aging, resulting in
misdiagnosis. Therefore, it is necessary to perform an overall inspection of the input/output systems and
AWD CM to determine which part is malfunctioning.
• With the AWD CM connector connected, measure voltage by connecting the voltmeter negative (-) lead to
the body ground and positive (+) lead to each AWD CM terminal.
1. Measure voltage or resistance at each AWD CM terminal using a voltmeter and an ohmmeter.
• If not as specified, replace the AWD CM.
Terminal Voltage List (Reference)

O M K I G E C A
P N L J H F D B

ac9uuw00001903

Input/ Connected Measuring Voltage (V)/ Inspection location

Terminal Signal Test condition
output to item Continuity in case of failure
Differential oil • Inspect
temperature 3.0 differential oil
Differential oil Differential oil
Ignition 20°C {68°F} temperature
A temperature Input temperature Voltage
key ON Differential oil sensor
sensor signal sensor
temperature 1.4 • Inspect related
60°C {140°F} harness
B — — — — — — — —
Differential oil Differential oil
• Inspect related
C temperature — temperature Continuity Any condition Yes
harness
sensor GND sensor
D — — — — — — — —
E — — — — — — — —
F — — — — — — — —
Input/
G CAN_H — Perform measurement during DTC inspection. —
output
Input/
H CAN_L — Perform measurement during DTC inspection. —
output
Power supply Ignition key ON B+ • Inspect fuse
I (Ignition Input Ignition key Voltage • Inspect related
switch) Ignition key OFF 1.0 or below harness
J — — — — — — — —
• Inspect fuse
Power supply
K Input Battery Voltage Any condition B+ • Inspect related
(Main)
harness
L — — — — — — — —
M — — — — — — — —
• Inspect related
N Ground — Ground Voltage Any condition 0
harness
Ignition key ON B+ • AWD solenoid
AWD solenoid
O Output AWD solenoid Voltage • Inspect related
(+) Ignition key OFF 1.0 or below harness
Ignition key ON B+ • AWD solenoid
AWD solenoid
P Output AWD solenoid Voltage • Inspect related
(-) Ignition key OFF 1.0 or below harness
End Of Sie

03-19–2
1890-1U-06H(03-19).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

AWD CONTROL MODULE REMOVAL/INSTALLATION
id031900800300
1. Disconnect the negative battery cable.
2. Remove the dashboard under cover (Driver side). (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

03-19

2
3

1 8.8—12.7
{90—129 , 78—112}

N·m { kgf· cm, in·lbf}

ac9uuw00001403

1 Bolt 3 Connector
2 AWD CM
(See 03-19-3 AWD CM Removal Note.)

AWD CM Removal Note

1. Push up the AWD CM slightly, and remove it.
End Of Sie
WM: COUPLING COMPONENT

AWD CM

ac9uuw00001404

03-19–3
1890-1U-06H(03-19).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

COUPLING COMPONENT REMOVAL/INSTALLATION
id031900800400
1. Drain the rear differential oil into a container.
2. Remove the under guard (LH). (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID
VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the presilencer. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the presilencer insulator. (See 07-11-17 REFRIGERANT LINE REMOVAL/INSTALLATION.)
5. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Add rear differential oil. (See 03-14-3 DIFFERENTIAL OIL REPLACEMENT.)

63—85
{6.5—8.6,
47—62}

3
SEALANT

2
1

4
22.6—26.4 63—85
{2.31—2.69, {6.5—8.6,
16.7—19.4} 3 47—62}

N·m {kgf·m, ft·lbf}

ac9uuw00001452

1 Differential oil temperature sensor connector 4 Coupling component

2 AWD solenoid connector (See 03-19-5 Front Differential Mounting Rubber
Removal Note)
3 Front differential mounting rubber (See 03-19-5 Coupling Component Removal Note)

03-19–4
1890-1U-06H(03-19).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

Front Differential Mounting Rubber Removal Note
1. Detach clips as shown in the figure. AWD SOLENOID CONNECTOR

ac9uuw00001373 03-19
2. Support the rear differential using a jack.
3. Remove the front differential mounting rubbers.

JACK

ac9uuw00001448

Coupling Component Removal Note

1. Support the coupling unit with a transmission jack.
2. Cut away the coupling unit using an oil pan seal
cutter.

OIL PAN
SEAL CUTTER

ac9uuw00001374

Coupling Component Installation Note

Note
• Clean away the old sealant before applying the new sealant.
• Install the coupling unit within 10 min after applying sealant.
• Allow the sealant to set at least 30 min after installation before filling the differential with the specified oil.

1. Apply sealant to the coupling case surface that contacts the rear differential case.
2. Install the coupling unit to the rear differential so
that the two tabs on the coupling unit engage the
rear differential grooves (two locations).

Tightening torque
22.6—26.4 N·m {2.31—2.69 kgf·m, 16.7—19.4
ft·lbf}

End Of Sie GROOVE

TAB
REAR DIFFERENTIAL COUPLING UNIT
ac9uuw00001375

03-19–5
1890-1U-06H(03-19).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

COUPLING COMPONENT DISASSEMBLY
id031900800500

Warning
• The engine stand is equipped with a self-lock mechanism, however, if the coupling unit is in a
tilted condition, the self-lock mechanism could become inoperative. If the coupling unit
unexpectedly rotates it could cause injury, therefore do not maintain the coupling unit in a tilted
condition. When turning the coupling unit, grasp the rotation handle firmly.

1. Disassemble in the order indicated in the table.

10

SST
9

7 5

6
SST 4
3 SST

2
SST
1

ac9uuw00001830

1 Locknut 5 Coupling component

(See 03-19-7 Locknut Disassembly Note) 6 Oil seal
2 Washer 7 Shim
3 Companion flange 8 Snap ring
(See 03-19-7 Companion Flange Disassembly
Note) 9 Bearing
(See 03-19-8 Bearing Disassembly Note)
4 Output shaft
(See 03-19-8 Output Shaft Disassembly Note) 10 Coupling case

03-19–6
1890-1U-06H(03-19).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

Locknut Disassembly Note
1. Assemble the SSTs to the engine stand.

49 L027 0A2

49 0107 680A

ac9uuw00001831 03-19
2. Install the coupling unit to the SSTs as shown.

49 L027 0A2

ac9uuw00001832

3. Secure the companion flange using the SST, and

remove the locknut.

49 S120 710

ac9uuw00001833

Companion Flange Disassembly Note

1. Remove the companion flange using the SST.

49 0839 425C

ac9uuw00001834

03-19–7
1890-1U-06H(03-19).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

Output Shaft Disassembly Note
1. Remove the coupling unit from the SST.
2. Install the coupling unit to the press as shown,
and remove the output shaft together with the
coupling unit.
3. Install the companion flange to the output shaft.

ac9uuw00001835

4. Secure the companion flange using the SST, and

remove the bolts.
5. Remove the output shaft.
49 S120 710

ac9uuw00001836

Bearing Disassembly Note

1. Remove the bearing using the SSTs and a press.
Substitution SST
• 49 S033 108 49 M005 797
Outer diameter: 33—55 mm {1.30—2.16 in}
Height: 155 mm {6.10 in} or more
End Of Sie

49 S033 108
ac9uuw00001837

03-19–8
1890-1U-06H(03-19).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

COUPLING COMPONENT ASSEMBLY
id031900800600

Warning
• The engine stand is equipped with a self-lock mechanism, however, if the coupling unit is in a
tilted condition, the self-lock mechanism could become inoperative. If the coupling unit
unexpectedly rotates it could cause injury, therefore do not maintain the coupling unit in a tilted
condition. When turning the coupling unit, grasp the rotation handle firmly.

1. Assemble in the order indicated in the table.

41.2—53.9 03-19
5 {4.2—5.4, 30.4—39.7}

SST 1
3 SST

4 2
6 SST

OIL
R
SST 7

SST R
167—226
{17.1—23.0,
124—166}
10

9 8
N·m {kgf·m, ft·lbf}

ac9uuw00001838

1 Coupling unit 6 Shim

2 Output shaft 7 Oil seal
(See 03-19-10 Output Shaft Assembly Note) (See 03-19-10 Oil Seal Assembly Note)
3 Bearing 8 Companion flange
(See 03-19-10 Bearing Assembly Note) (See 03-19-11 Companion Flange Assembly Note)
4 Snap ring 9 Washer
5 Coupling case 10 Locknut
(See 03-19-10 Coupling Case Assembly Note) (See 03-19-11 Locknut Assembly Note)

03-19–9
1890-1U-06H(03-19).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

Output Shaft Assembly Note
1. Install the output shaft to the coupling unit and partially tighten the bolts.
2. Install the companion flange to the output shaft.
3. Secure the companion flange using the SST, and
tighten the bolts. 49 S120 710
Tightening torque
41.2—53.9 N·m {4.2—5.4 kgf·m, 30.4—39.7
ft·lbf}

ac9uuw00001839
Bearing Assembly Note
1. Assemble the bearing to the coupling case using
the SSTs.
Substitution SST 49 G030 797
• 49 G030 796
Outer diameter: 58—61 mm {2.29—2.40 in}
49 G030 796

ac9uuw00001840
Coupling Case Assembly Note

Caution
• The coupling unit will be damaged if it is pressed directly by a press. Always press the coupling
unit into the coupling case using the SST.

1. Assemble the coupling unit to the coupling case

using the SSTs and a press.
Substitution SST 49 W010 107A
• 49 S032 333
Outer diameter: 34.2—40.0 mm {1.35—1.57
in}
Inner diameter: 30.2—32.2 mm {1.19—1.26
in}
Inner depth: 65.2 mm {2.57 in} or more 49 S032 333

ac9uuw00001841

Oil Seal Assembly Note

1. Apply the specified oil to a new oil seal lip.
2. Install the oil seal to the coupling case using the
SST.
Substitution SST
• 49 W011 102 49 W011 102
Outer diameter: 66 mm {2.60 in} or more
Inner diameter: 54—60 mm {2.13—2.36 in}
Inner depth: 17.5 mm {0.69 in} or more

ac9uuw00001842

03-19–10
1890-1U-06H(03-19).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

Companion Flange Assembly Note
1. Install the coupling case to the SSTs as shown.
2. Install the companion flange.

49 L027 0A2

ac9uuw00001843 03-19
Locknut Assembly Note
1. Secure the companion flange using the SST, and
tighten a new locknut.
49 S120 710
Tightening torque
167—226 N·m {17.1—23.0 kgf·m, 124—166
ft·lbf}

End Of Sie
WM: DIFFERENTIAL OIL TEMPERATURE SENSOR

ac9uuw00001844
DIFFERENTIAL OIL TEMPERATURE SENSOR INSPECTION
id031900800700

Warning
• Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is
hot.

1. Disconnect the negative battery cable.

2. Disconnect the differential oil temperature sensor connector and remove the differential oil temperature sensor.
3. Wrap the differential oil temperature sensor with
plastic wrap and immerse it into a beaker filled
with water. Gradually raise the water temperature,
and measure resistance between differential oil
temperature sensor terminals A and B.
• If not as specified, inspect the harness for B A
continuity. If there is normal continuity
between the terminals, replace the differential
oil temperature sensor.

ac9uuw00001904

Differential oil temperature sensor specification

Water temperature (°C {°F}) Resistance (kirohm)
0 {32} 91—100
10 {50} 56—61
20 {68} 35—39
30 {86} 23—25
40 {104} 14—17
50 {122} 10—11
60 {140} 7.1—7.9
70 {158} 5.0—5.6
80 {176} 3.6—4.0

4. Install the differential oil temperature sensor and connect the connector.
5. Connect the negative battery cable.
03-19–11
1890-1U-06H(03-19).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時２８分

ALL WHEEL DRIVE (AWD)

End Of Sie

DIFFERENTIAL OIL TEMPERATURE SENSOR REMOVAL/INSTALLATION

id031900800800

Warning
• Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is
hot.

1. Disconnect the negative battery cable.

2. Disconnect the differential oil temperature sensor connector.
3. Remove the differential oil temperature sensor.
4. Apply differential oil to the O-ring.
5. Install the differential oil temperature sensor.

Tightening torque
12.7—17.3 N·m {1.3—1.7 kgf·m, 9.4—12.7
ft·lbf}

6. Connect the differential oil temperature sensor

connector. DIFFERENTIAL OIL
TEMPERATURE SENSOR
7. Connect the negative battery cable.
End Of Sie
WM: 4WD SOLENOID ac9uuw00001905

AWD SOLENOID INSPECTION

id031900800900
1. Disconnect the negative battery cable.
2. Disconnect the AWD solenoid connector.
3. Measure resistance between AWD solenoid
connector terminals A and B.
• If the resistance is not within the specification,
replace the coupling unit.
B A
AWD solenoid resistance
1.5—2.0 ohms
(Rear differential oil temperature at 20°C
{68°F})

4. Connect the AWD solenoid connector.

5. Connect the negative battery cable.
ac9uuw00001906
End Of Sie

03-19–12
1890-1U-06H(03-50).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時２９分

TECHNICAL DATA
03-50 TECHNICAL DATA
DRIVELINE/AXLE
TECHNICAL DATA . . . . . . . . . . . . . . . . 03-50–1

End of Toc
DRIVELINE/AXLE TECHNICAL DATA
WM: DRIVELINE/AXLE

id035000800100
Front and Rear Axle
Item Specification
Front wheel bearing maximum play 0.05 mm {0.002 in}
Rear wheel bearing maximum play 0.05 mm {0.002 in} 03-50
Drive Shaft
Item Specification
LH: 658.7—668.7 mm {25.92—26.30 in}
Front drive shaft standard length
RH: 630.7—640.7 mm {24.82—25.20 in}
LH: 840.3—850.3 mm {33.09—33.47 in}
Rear drive shaft standard length
RH: 895.3—905.3 mm {35.25—35.64 in}

Differential
Item Specification
Grade: API service GL-5
Rear differential oil Viscosity: SAE 80W-90
Capacity (approximate quantity): 1.0 L {1.1 US qt, 0.9 Imp qt}
Rear differential backlash of pinion gear and side gear 0.1 mm {0.004 in} or less
Rear differential pinion height –0.032—0.032 mm {–0.0012—0.0012 in}
Rear differential drive pinion preload 1.3—1.8 N·m {13.3—18.2 kgf·cm, 11.5—15.9 in·lbf}
Standard: 0.09—0.11 mm {0.003—0.004 in}
Rear differential backlash of drive pinion and ring gear
Minimum value: 0.05 mm {0.002 in}

Propeller Shaft
Item Specification
Propeller shaft maximum runout 0.8 mm {0.031 in}
Propeller shaft starting torque 0.29—1.47 N·m {3.0—14.9 kgf·cm, 2.6—13.0 in·lbf}

End Of Sie

03-50–1
1890-1U-06H(03-60).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時３１分

SERVICE TOOLS
03-60 SERVICE TOOLS
DRIVELINE/AXLE SST . . . . . . . . . . . . . . 03-60–1

End of Toc
DRIVELINE/AXLE SST
WM: DRIVELINE/AXLE

id036000800200
Front and Rear Axle
49 T028 3A0 49 G033 102
49 G033 105
Ball joint puller Handle
set Attachment
03-60
49 F026 103 49 G033 106 49 G033 107A

Wheel hub Attachment Dust cover

puller installer

49 F027 009 49 F027 003 49 F027 004

Attachment ø68 Handle Attachment ø80

& 77

49 B025 004

Dust seal
installer — —

Drive Shaft
49 B025 017 49 B025 016 49 0223 630B

Sliding hammer Extension Rear shaft

(Part of 49 B025 (Part of 49 B025 puller body
0A1) 0A2)

49 B025 010 49 B025 0A1 49 B025 0A2

Attachment A Remover set Remover set

(Part of 49 B025
0A1)
(Part of 49 B025
0A2)
49 B014 001 49 W034 301 49 B025 004

Oil seal installer Support block Dust seal

installer

49 V001 525 49 T025 001

Bearing installer Boot clamp —

crimpers

03-60–1
1890-1U-06H(03-60).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時３１分

SERVICE TOOLS
Differential
49 G030 796 49 G030 797 49 S120 710

Oil seal installer Handle Coupling flange

holder

49 0839 425C 49 W011 102 49 B025 010

Bearing puller Oil seal installer Attachment A

set

49 L027 0A2 49 0107 680A 49 T032 317

Diff hanger set Engine stand Weight

49 T032 316 49 L027 004 49 L027 006

Shaft Gear case Serrate socket

remover

49 L027 007 49 H027 002 49 F401 331

Hex socket Bearing Bearing installer

remover body

49 G030 338 49 M005 797 49 F027 007

Attachment E Oil seal installer Attachment ø72

49 F027 004 49 0305 555 49 8531 565

Attachment ø80 Gauge block Drive pinion

model

49 8531 568 49 G027 005 49 G032 347

Collar Collar Oil seal installer

49 0727 570 49 V001 525 49 S033 108

Pinion height Bearing installer Bearing installer

gauge body

49 W010 107A 49 S032 333

Oil seal installer Bearing installer —

03-60–2
1890-1U-06H(03-60).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時３１分

SERVICE TOOLS
Transfer
49 B032 334 49 S231 660

Installer bearing Puller needle

bearing —

End Of Sie

03-60

03-60–3
1890-1U-06H(04-02).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

BRAKES 04SECTION

Toc of SCT
ON-BOARD DIAGNOSTIC PARKING
[DSC/RSC] . . . . . . . . . . . . . . . 04-02 BRAKE SYSTEM . . . . . . . . . . 04-12
SYMPTOM DYNAMIC STABILITY
TROUBLESHOOTING CONTROL/ROLL
[DSC/RSC] . . . . . . . . . . . . . . . 04-03 STABILITY CONTROL. . . . . . 04-18
GENERAL PROCEDURES . . . . 04-10 TECHNICAL DATA . . . . . . . . . . 04-50 04-02
CONVENTIONAL SERVICE TOOLS . . . . . . . . . . . 04-60
BRAKE SYSTEM . . . . . . . . . . 04-11
Toc of SCT
04-02 ON-BOARD DIAGNOSTIC [DSC/RSC]
SYSTEM WIRING DIAGRAM DTC C1145, C1155, C1165, C1175
[DSC/RSC] . . . . . . . . . . . . . . . . . . . . . . . 04-02–2 [DSC/RSC]. . . . . . . . . . . . . . . . . . . . . . . 04-02–15
ON-BOARD DIAGNOSIS DTC C1194, C1198, C1210, C1214,
[DSC/RSC] . . . . . . . . . . . . . . . . . . . . . . . 04-02–3 C1242, C1246, C1250, C1254, C1404,
On-Board Diagnostic (OBD) C1410, C1957, C1958
Test Description . . . . . . . . . . . . . . . . . 04-02–3 [DSC/RSC]. . . . . . . . . . . . . . . . . . . . . . . 04-02–17
Reading DTCs Procedure . . . . . . . . . . . 04-02–3 DTC C1222 [DSC/RSC]. . . . . . . . . . . . . . 04-02–18
Clearing DTCs Procedures . . . . . . . . . . 04-02–3 DTC C1233, C1234, C1235, C1236
PID/Data Monitor and [DSC/RSC]. . . . . . . . . . . . . . . . . . . . . . . 04-02–19
Record Procedure . . . . . . . . . . . . . . . . 04-02–4 DTC C1278, C1295, U2023
Active Command Modes [DSC/RSC]. . . . . . . . . . . . . . . . . . . . . . . 04-02–20
Procedure . . . . . . . . . . . . . . . . . . . . . . 04-02–4 DTC C1288 [DSC/RSC]. . . . . . . . . . . . . . 04-02–20
DTC Table . . . . . . . . . . . . . . . . . . . . . . . 04-02–5 DTC C1327 [DSC/RSC]. . . . . . . . . . . . . . 04-02–21
PID/DATA Monitor Table . . . . . . . . . . . . 04-02–7 DTC C1329, C1330, C1331, C1332,
Active Command Modes Table . . . . . . . 04-02–9 C1333, C1334, C1335, C1336, C1527,
DTC B1317, B1318 [DSC/RSC] . . . . . . . . 04-02–10 C1528, C1530, C1531
DTC B1342, C1730 [DSC/RSC] . . . . . . . . 04-02–11 [DSC/RSC]. . . . . . . . . . . . . . . . . . . . . . . 04-02–21
DTC B211B, C1279, C1280, C1281, DTC C1446 [DSC/RSC]. . . . . . . . . . . . . . 04-02–22
C1282, C1516, C1517, C2769, C2770 DTC C1963 [DSC/RSC]. . . . . . . . . . . . . . 04-02–24
[DSC/RSC] . . . . . . . . . . . . . . . . . . . . . . . 04-02–12 DTC C1991 [DSC/RSC]. . . . . . . . . . . . . . 04-02–24
DTC C1095, C1096 [DSC/RSC] . . . . . . . . 04-02–12 DTC U1901 [DSC/RSC]. . . . . . . . . . . . . . 04-02–24
DTC C1115, C1185 [DSC/RSC] . . . . . . . . 04-02–14

End of Toc
WM: ROLL STABILITY CONTROL

04-02–1
1890-1U-06H(04-02).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

SYSTEM WIRING DIAGRAM [DSC/RSC]
id0402b3810000

ABS (SOL) 30A TCS OFF LIGHT DSC INDICATOR

AL
LIGHT
ABS WARNING BRAKE SYSTEM
LIGHT WARNING LIGHT

IG 1
ABS 50A
AK

B
SAS 7.5A
X
IG SW

BATTERY

INSTRUMENT CLUSTER

PCM
E CAN2_L
COMBINED C M
SENSOR D P DSC/RSC HU/CM +B
CAN2_H
B
HS_CAN_H
Y
V STEERING
HS_CAN_L
BCM ANGLE
SENSOR

AE
RF
AB

AG DLC-2
LF
AD
ABS WHEEL-
SPEED SENSOR
RR G
J

TCS OFF SWITCH

LR F
I U

ac9uuw00002263

End Of Sie

04-02–2
1890-1U-06H(04-02).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

ON-BOARD DIAGNOSIS [DSC/RSC]
id0402b3810100
On-Board Diagnostic (OBD) Test Description
• The OBD test inspects the integrity and function of the DSC/RSC and outputs the results when requested by
the specific tests.
• On-board diagnostic test also:
— Provides a quick inspection of the DSC/RSC usually performed at the start of each diagnostic procedure.
— Provides verification after repairs to ensure that no other faults occurred during service.
• The OBD test is divided into 3 tests:
— Read/clear diagnostic results, PID monitor and record and active command modes.

Read/clear diagnostic results

• This function allows you to read or clear DTCs in the DSC/RSC HU/CM memory.

PID/Data monitor and record

• This function allows you to access certain data values, input signals, calculated values, and system status 04-02
information.

Active command modes

• This function allows you to control devices through the M-MDS.

Reading DTCs Procedure

1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “ABS”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “ABS”.
3. Select “Self Test”.
ac9uuw00000862
3. Verify the DTC according to the directions on the
screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
4. After completion of repairs, clear all DTCs stored in the DSC/RSC. (See 04-02-3 Clearing DTCs Procedures.)

Clearing DTCs Procedures

1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “ABS”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “ABS”.
3. Select “Self Test”.
ac9uuw00000862
3. Verify the DTC according to the directions on the
screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.

04-02–3
1890-1U-06H(04-02).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

PID/Data Monitor and Record Procedure
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “ABS”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “ABS”.
3. Select “DataLogger”.
ac9uuw00000862
3. Select the applicable PID from the PID table.
4. Verify the PID data according to the directions on
the screen.

Note
• The PID/Data monitor function is used for monitoring the calculated value. Therefore, if the monitored
value of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually using a active command modes function.

Active Command Modes Procedure

1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “ABS”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “ABS”.
3. Select “DataLogger”.
ac9uuw00000862
3. Select the active command modes from the PID
table.
4. Perform the active command modes, inspect the operations for each parts.
• If there is no operation sound from the relay, motor, and solenoid after the active command mode
inspection is performed, it is possible that there is an open or short circuit in the wiring harness, relay, motor
or solenoid, or sticking and operation malfunction.

04-02–4
1890-1U-06H(04-02).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC Table
DTC
System malfunction location Page
M-MDS
B1317 Power supply system (See 04-02-10 DTC B1317, B1318 [DSC/RSC].)
B1318 Power supply system (See 04-02-10 DTC B1317, B1318 [DSC/RSC].)
B1342 DSC/RSC HU/CM system (See 04-02-11 DTC B1342, C1730 [DSC/RSC].)
(See 04-02-12 DTC B211B, C1279, C1280, C1281, C1282,
B211B Combined sensor system
C1516, C1517, C2769, C2770 [DSC/RSC].)
C1095 Pump motor, motor relay system (See 04-02-12 DTC C1095, C1096 [DSC/RSC].)
C1096 Pump motor, motor relay system (See 04-02-12 DTC C1095, C1096 [DSC/RSC].)
C1115 Valve relay system (See 04-02-14 DTC C1115, C1185 [DSC/RSC]
RF ABS wheel-speed sensor (open circuit) (See 04-02-15 DTC C1145, C1155, C1165, C1175 [DSC/
C1145
system RSC].)
LF ABS wheel-speed sensor (open circuit) (See 04-02-15 DTC C1145, C1155, C1165, C1175 [DSC/ 04-02
C1155
system RSC].)
RR ABS wheel-speed sensor (open circuit) (See 04-02-15 DTC C1145, C1155, C1165, C1175 [DSC/
C1165
system RSC].)
LR ABS wheel-speed sensor (open circuit) (See 04-02-15 DTC C1145, C1155, C1165, C1175 [DSC/
C1175
system RSC].)
C1185 Valve relay system (See 04-02-14 DTC C1115, C1185 [DSC/RSC]
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1194 LF outlet solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1198 LF inlet solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1210 RF outlet solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1214 RF inlet solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
C1222 ABS wheel-speed sensor system (See 04-02-18 DTC C1222 [DSC/RSC].)
LF ABS wheel-speed sensor/ABS sensor rotor (See 04-02-19 DTC C1233, C1234, C1235, C1236 [DSC/
C1233
system RSC].)
RF ABS wheel-speed sensor/ABS sensor rotor (See 04-02-19 DTC C1233, C1234, C1235, C1236 [DSC/
C1234
system RSC].)
RR ABS wheel-speed sensor/ABS sensor rotor (See 04-02-19 DTC C1233, C1234, C1235, C1236 [DSC/
C1235
system RSC].)
LR ABS wheel-speed sensor/ABS sensor rotor (See 04-02-19 DTC C1233, C1234, C1235, C1236 [DSC/
C1236
system RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1242 LR outlet solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1246 RR outlet solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1250 LR inlet solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1254 RR inlet solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
C1278 Steering angle sensor system (See 04-02-20 DTC C1278, C1295, U2023 [DSC/RSC].)
(See 04-02-12 DTC B211B, C1279, C1280, C1281, C1282,
C1279 Combined sensor system
C1516, C1517, C2769, C2770 [DSC/RSC].)
(See 04-02-12 DTC B211B, C1279, C1280, C1281, C1282,
C1280 Combined sensor system
C1516, C1517, C2769, C2770 [DSC/RSC].)
(See 04-02-12 DTC B211B, C1279, C1280, C1281, C1282,
C1281 Combined sensor system
C1516, C1517, C2769, C2770 [DSC/RSC].)

04-02–5
1890-1U-06H(04-02).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC
System malfunction location Page
M-MDS
(See 04-02-12 DTC B211B, C1279, C1280, C1281, C1282,
C1282 Combined sensor system
C1516, C1517, C2769, C2770 [DSC/RSC].)
C1288 Brake fluid pressure sensor system (See 04-02-20 DTC C1288 [DSC/RSC]
C1295 Steering angle sensor system (See 04-02-20 DTC C1278, C1295, U2023 [DSC/RSC].)
C1327 Brake fluid level sensor system (See 04-02-21 DTC C1327 [DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1329 RF outlet solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1330 LR outlet solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1331 RR outlet solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1332 LF outlet solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1333 LR inlet solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1334 LF inlet solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1335 RF inlet solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1336 RR inlet solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1404 RH traction control solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1410 LH traction control solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
C1446 Brake switch system (See 04-02-22 DTC C1446 [DSC/RSC].)
(See 04-02-12 DTC B211B, C1279, C1280, C1281, C1282,
C1516 Combined sensor system
C1516, C1517, C2769, C2770 [DSC/RSC].)
(See 04-02-12 DTC B211B, C1279, C1280, C1281, C1282,
C1517 Combined sensor system
C1516, C1517, C2769, C2770 [DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1527 RH traction control solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1528 LH traction control solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1530 RH stability control solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See 04-02-21 DTC C1329, C1330, C1331, C1332, C1333,
C1531 LH stability control solenoid valve coil system C1334, C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
C1730 DSC/RSC HU/CM system (See 04-02-11 DTC B1342, C1730 [DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1957 RH stability control solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See 04-02-17 DTC C1194, C1198, C1210, C1214, C1242,
C1958 LH stability control solenoid valve system C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
Combined sensor (Yaw rate sensor part) initial
C1963 (See 04-02-24 DTC C1963 [DSC/RSC].)
point correction error

04-02–6
1890-1U-06H(04-02).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC
System malfunction location Page
M-MDS
DSC/RSC sensor (abnormal initialization)
C1991 (See 04-02-24 DTC C1991 [DSC/RSC].)
system
(See 04-02-12 DTC B211B, C1279, C1280, C1281, C1282,
C2769 Combined sensor system
C1516, C1517, C2769, C2770 [DSC/RSC].)
(See 04-02-12 DTC B211B, C1279, C1280, C1281, C1282,
C2770 Combined sensor system
C1516, C1517, C2769, C2770 [DSC/RSC].)
(See 09-02L-8 DTC TABLE [MULTIPLEX
U0073 CAN system communication error
COMMUNICATION SYSTEM].)
(See 09-02L-8 DTC TABLE [MULTIPLEX
U0100 Communication error to PCM
COMMUNICATION SYSTEM].)
(See 09-02L-8 DTC TABLE [MULTIPLEX
U0140 Communication error to BCM
COMMUNICATION SYSTEM].)
U0155 Communication error to instrument cluster
(See 09-02L-8 DTC TABLE [MULTIPLEX 04-02
COMMUNICATION SYSTEM].)
Combined sensor system (CAN2 line
U1901 (See 04-02-24 DTC U1901 [DSC/RSC].)
malfunction)
U2023 Steering angle sensor system (See 04-02-20 DTC C1278, C1295, U2023 [DSC/RSC].)

PID/DATA Monitor Table

Operation condition DSC/RSC HU/
PID name (definition) Unit/Condition Action
(reference) CM terminal
• Vehicle stopped or driving
at constant speed: 0 G
• Vehicle is driving at a
Inspect the combined sensor.
acceleration: changes 0
ACCLMTR G (See 04-18-17 COMBINED —
G—positive
SENSOR INSPECTION.)
• Vehicle is driving at a
deceleration: changes 0
G—negative
BOO_ABS • Brake pedal depressed: Inspect the brake switch.
(Brake pedal switch Off/On On (See 04-11-7 BRAKE SWITCH —
input) • Brake pedal released: Off INSPECTION.)
CCNTABS
Perform the DTC inspection.
(Number of continuous — Indicates number of DTC —
(See 04-02-5 DTC Table.)
codes)
• Vehicle stopped or driving
at constant speed: 0 G
Inspect the combined sensor.
• Cornering to right:
LAT_ACCL G (See 04-18-17 COMBINED —
Changes 0 G—positive
SENSOR INSPECTION.)
• Cornering to left: Changes
0 G—negative
• Brake pedal released: 0 Inspect the brake fluid pressure
Pa, 0 psi sensor.
MCYLI P Pa, psi • Brake pedal depressed: (See 04-18-19 BRAKE FLUID —
Changes according to the PRESSURE SENSOR
brake fluid pressure INSPECTION.)
PMP_MOTOR • Pump motor activated: On Inspect the DSC/RSC HU/CM.
(Pump motor output Off/On • Pump motor not activated: (See 04-18-4 DSC/RSC SYSTEM —
state) Off INSPECTION.)
• Selector lever position P: Inspect the TCM.
SHIFT_P
On (See 05-17-22 TCM
(Transaxle gear Off/On —
• Other than those above: INSPECTION [AW6A-EL,
position input)
Off AW6AX-EL].)
PWR_RLY • Valve relay activated: On Inspect the DSC/RSC HU/CM.
(Valve relay output Off/On • Valve relay not activated: (See 04-18-4 DSC/RSC SYSTEM —
state) Off INSPECTION.)
• Vehicle stopped or driving
straight: 0 °/s
Inspect the combined sensor.
ROLL_RATE • Cornering to left: 0 °/s—
°/s (See 04-18-17 COMBINED —
(Roll rate sensor input) positive
SENSOR INSPECTION.)
• Cornering to right: 0 °/s—
negative

04-02–7
1890-1U-06H(04-02).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

Operation condition DSC/RSC HU/
PID name (definition) Unit/Condition Action
(reference) CM terminal
• Steering wheel neutral
position(not turned): 0 °
• Steering wheel turned to
SWA_POS Inspect the steering angle sensor.
left: Changes 0 °—
(Steering angle sensor ° (See 09-40-10 STEERING —
negative
input) ANGLE SENSOR INSPECTION.)
• Steering wheel turned to
right: Changes 0 °—
positive
• TCS OFF switch is
Inspect the TCS OFF switch.
TCS_OFF_SW depressed: On
Off/On (See 04-18-20 TCS OFF SWITCH U
(TCS OFF switch input) • TCS OFF switch is
INSPECTION.)
released* Off
• Solenoid valve activated:
V_LF_INL Inspect the DSC/RSC HU/CM.
On
(Left front inlet solenoid Off/On (See 04-18-4 DSC/RSC SYSTEM —
• Solenoid valve not
valve output state) INSPECTION.)
activated: Off
V_LF_OTL • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(Left front outlet On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
• Solenoid valve activated:
V_LR_INL Inspect the DSC/RSC HU/CM.
On
(Left rear inlet solenoid Off/On (See 04-18-4 DSC/RSC SYSTEM —
• Solenoid valve not
valve output state) INSPECTION.)
activated: Off
V_LR_OTL • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(Left rear outlet On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_RF_INL • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(Right front inlet On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_RF_OTL • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(Right front outlet On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_RR_INL • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(Right rear inlet On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_RR_OTL • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(Right rear outlet On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_STB_L • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(LH stability control On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_STB_R • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(RH stability control On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_TRC_L • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(LH traction control On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_TRC_R • Solenoid valve activated:
Inspect the DSC/RSC HU/CM.
(RH traction control On
Off/On (See 04-18-4 DSC/RSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off

04-02–8
1890-1U-06H(04-02).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

Operation condition DSC/RSC HU/
PID name (definition) Unit/Condition Action
(reference) CM terminal
Inspect the ABS wheel-speed
• Vehicle stopped: 0 KPH, 0
WSPD_LF sensor.
MPH
(Left front ABS wheel- KPH, MPH (See 04-18-12 FRONT ABS AG, AD
• Vehicle running: vehicle
speed sensor input) WHEEL-SPEED SENSOR
speed
INSPECTION.)
Inspect the ABS wheel-speed
sensor.
• Vehicle stopped: 0 KPH, 0 (See 04-18-14 REAR ABS
WSPD_LR
MPH WHEEL-SPEED SENSOR
(Left rear ABS wheel- KPH, MPH F, I
• Vehicle running: vehicle INSPECTION [2WD].)
speed sensor input)
speed (See 04-18-15 REAR ABS
WHEEL-SPEED SENSOR
INSPECTION [AWD].)
Inspect the ABS wheel-speed
• Vehicle stopped: 0 KPH, 0 04-02
WSPD_RF sensor.
MPH
(Right front ABS wheel- KPH, MPH (See 04-18-12 FRONT ABS AE, AB
• Vehicle running: vehicle
speed sensor input) WHEEL-SPEED SENSOR
speed
INSPECTION.)
Inspect the ABS wheel-speed
sensor.
• Vehicle stopped: 0 KPH, 0 (See 04-18-14 REAR ABS
WSPD_RR
MPH WHEEL-SPEED SENSOR
(Right rear ABS wheel- KPH, MPH G, J
• Vehicle running: vehicle INSPECTION [2WD].)
speed sensor input)
speed (See 04-18-15 REAR ABS
WHEEL-SPEED SENSOR
INSPECTION [AWD].)
• Vehicle stopped or driving
straight: 0 °/s
Inspect the combined sensor.
• Cornering to left: Changes
YAW_RATE °/s (See 04-18-17 COMBINED —
0 °/s—negative
SENSOR INSPECTION.)
• Cornering to right:
Changes 0 °/s—positive

Active Command Modes Table

Operating
Command name Output part Operation
condition
PMP_MOTOR Pump motor
PWR_RLY Valve relay
SSR_INTL DSC/RSC sensor initialization
V_LF_INL LF inlet solenoid valve
V_LF_OTL LF outlet solenoid valve
V_LR_INL LR inlet solenoid valve
V_LR_OTL LR outlet solenoid valve
Ignition switch at
V_RF_INL RF inlet solenoid valve Off/On
ON
V_RF_OTL RF outlet solenoid valve
V_RR_INL RR inlet solenoid valve
V_RR_OTL RR outlet solenoid valve
V_STB_L LH stability control solenoid valve
V_STB_R RH stability control solenoid valve
V_TRC_L LH traction control solenoid valve
V_TRC_R RH traction control solenoid valve

End Of Sie
WM: DTC

04-02–9
1890-1U-06H(04-02).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC B1317, B1318 [DSC/RSC]
id0402b3800300

Note
• DTC B1317 is output when the battery voltage is 16 V or more. If DTC B1317 is output, inspect the battery
and charging system for a malfunction before performing the malfunction diagnosis.

DTC B1317, B1318 Power supply system

• B1317
— DSC/RSC HU/CM terminal X voltage of 16 V or more continues for 3 s while driving at a vehicle
speed of 8 km/h or more.
DETECTION — DSC/CM terminal X voltage of 18.5 V or more continues for 15 ms while driving at a vehicle speed of
CONDITION 8 km/h or more.
• B1318
— DSC/RSC HU/CM terminal X voltage of 10 V or less continues for 3 s while driving at a vehicle
speed of 8 km/h or more.
• SAS 7.5A fuse malfunction
• Open circuit or short to ground in the wiring harness between the DSC/RSC HU/CM terminal X and the
battery
POSSIBLE • Open circuit or faulty ground in the wiring harness between the DSC/RSC HU/CM terminal A and the
CAUSE body ground
• Battery deterioration
• Generator malfunction
• Poor connection at connectors (female terminal)
IG SW
X
SAS 7.5A
DSC/RSC HU/CM

A
BATTERY

DSC/RSC HU/CM WIRING HARNESS-SIDE CONNECTOR

AK AH AE AB Y V S P M J G D B
AI AF AC Z W T Q N K H E

AL AJ AG AD AA X U R O L I F C A

04-02–10
1890-1U-06H(04-02).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DSC/RSC HU/CM POWER SUPPLY Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Start the engine. between the DSC/RSC HU/CM and ground, then go to Step
• Measure the voltage between DSC/RSC HU/ 3.
CM terminal X and ground.
• Is the voltage approx. 10 V?
2 INSPECT DSC/RSC HU/CM GROUND FOR Yes Go to the next step.
POOR GROUND OR OPEN CIRCUIT No If there is no continuity:
• Turn the ignition switch off. • Repair or replace the wiring harness for open circuit
• Measure the resistance between ground and between the DSC/RSC HU/CM and ground, then go to
DSC/RSC HU/CM terminal A. the next step.
• Is the resistance within 0—1 ohm? If the resistance is not within 0—1 ohm:
• Repair or replace the wiring harness for poor ground,
then go to the next step. 04-02
3 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the DSC/RSC HU/CM, then go to the next step.
• Make sure to reconnect all disconnected (See 04-18-6 DSC/RSC HU/CM REMOVAL/
connectors. INSTALLATION.)
• Clear the DTC from the memory. No Go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS
[DSC/RSC].)
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
No DTC troubleshooting completed.

End Of Sie
DTC B1342, C1730 [DSC/RSC]
id0402b3800400

Note
• Perform the inspection of DTCs other than B1342 and C1730 first when verifying DTCs.

DTC B1342, C1730 DSC/RSC HU/CM system

• B1342
DETECTION — DSC/RSC HU/CM on-board diagnostic function detects control module malfunction.
CONDITION • C1730
— Sensor supply voltage is out of range.
POSSIBLE
• DSC/RSC HU/CM internal malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY DTC INSPECTION Yes Go to the applicable DTC inspection.
• Turn the ignition switch off. (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
• Using the M-MDS, perform the DTC No Go to the next step.
inspection.
• Are any DTCs other than B1342 and C1730
output?
2 VERIFY CURRENT STATUS OF Yes Replace the DSC/RSC HU/CM, then go to the next step.
MALFUNCTION (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Clear the DTC from the memory. INSTALLATION.)
(See 04-02-3 ON-BOARD DIAGNOSIS No Go to the next step.
[DSC/RSC].)
• Is the same DTC present?
3 VERIFY THAT NO DTCS ARE OUTPUT AGAIN Yes If DTC B1342 or C1730 is output again, replace the DSC/
• Drive the vehicle at 32km/h or more. RSC HU/CM.
• Stop the vehicle and verify the DTCs. (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Are DTCs output again? INSTALLATION.)
No DTC troubleshooting completed.

End Of Sie

04-02–11
1890-1U-06H(04-02).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC B211B, C1279, C1280, C1281, C1282, C1516, C1517, C2769, C2770 [DSC/RSC]
id0402b3815100

B211B, C1279, C1280, C1281, C1282, Combined sensor system

DTC
C1516, C1517, C2769, C2770
• B211B
— Combined sensor internal malfunction.
• C1279
— There is an abnormality in the signal from the combined sensor (yaw rate part).
• C1280
— Specified signal from combined (yaw rate part) sensor has not output.
• C1281
— There is an abnormality in the signal from the combined sensor (lateral-G part).
DETECTION • C1282
CONDITION — Specified signal from combined (lateral-G part) sensor has not output.
• C1516
— Specified signal from combined (roll rate part) sensor has not output.
• C1517
— There is an abnormality in the signal from the combined sensor (roll rate part).
• C2769
— There is an abnormality in the signal from the combined sensor (longitudinal-G part).
• C2770
— Specified signal from combined (longitudinal-G part) sensor has not output.
POSSIBLE • Combined sensor malfunction
CAUSE • Poor connection at connectors (female terminal)

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT COMBINED SENSOR Yes Go to the next step.
• Inspect the combined sensor. No Replace the combined sensor, then go to the next step.
(See 04-18-17 COMBINED SENSOR (See 04-18-16 COMBINED SENSOR REMOVAL/
INSPECTION.) INSTALLATION.)
• Is the combined sensor normal?
2 VERIFY DTC TROUBLESHOOTING Yes Replace the DSC/RSC HU/CM, then go to the next step.
COMPLETED. (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Clear the DTC from the memory. INSTALLATION.)
(See 04-02-3 ON-BOARD DIAGNOSIS No Go to the next step.
[DSC/RSC].)
• Are the same DTCs present?
3 VERIFY AFTER REPAIR PROCEDURE. Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
No DTC troubleshooting completed.

End Of Sie
DTC C1095, C1096 [DSC/RSC]
id0402b3800800

DTC C1095, C1096 Pump motor, motor relay system

• C1095
— ABS motor monitor OFF signal is input within specified time limit when the motor signal is switched
DETECTION
from ON to OFF by DSC/RSC HU/CM.
CONDITION
• C1096
— When pump motor monitor voltage continues for 0.05s more than 0.75V among the pump motor ON.
• ABS 50A fuse malfunction
• Open or short to ground circuit in the wiring harness between the battery and the DSC/RSC HU/CM
terminal AK
POSSIBLE • Open circuit in the wiring harness between the DSC/RSC HU/CM terminal B and the body ground
CAUSE • Open or short circuit in the DSC/RSC HU/CM internal motor relay, or stuck motor relay
• Open or short circuit in the DSC/RSC HU/CM internal motor, or frozen motor
• Motor relay malfunction
• Poor connection at connectors (female terminal)

04-02–12
1890-1U-06H(04-02).fm 13 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DSC/RSC HU/CM
AK
ABS 50A

PUMP
BATTERY MOTOR
B

DSC/RSC HU/CM WIRING HARNESS-SIDE CONNECTOR

AK AH AE AB Y V S P M J G D B
AI AF AC Z W T Q N K H E

AL A 04-02
AJ AG AD AA X U R O L I F C

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT ABS FUSE CONDITION Yes Go to the next step.
• Is the ABS 50A fuse normal? No Replace the fuse, then go to Step 5.
2 INSPECT MOTOR RELAY POWER SUPPLY Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the ignition switch off. between battery positive terminal and DSC/RSC HU/CM
• Disconnect DSC/RSC HU/CM connector. terminal AK, then go to Step 5.
• Turn the ignition switch to the ON position
(engine off).
• Measure voltage between DSC/RSC HU/CM
terminal AK (harness-side) and ground.
• Is the voltage B+?
3 INSPECT PUMP MOTOR GROUND FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the ignition switch off. between DSC/RSC HU/CM terminal B and ground, then go
• Inspect for continuity between DSC/RSC HU/ to Step 5.
CM terminal B (harness-side) and ground.
• Is there continuity?
4 VERIFY PUMP MOTOR OPERATION Yes Go to the next step.
• Turn the ignition switch off. No Replace the DSC/RSC HU/CM, then go to the next step.
• Connect the M-MDS to the DLC-2. (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Turn the ignition switch to the ON position INSTALLATION.)
(engine off).
• Access PMP_MOTOR active command
modes using the M-MDS.
• Does the pump motor operate?
5 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the DSC/RSC HU/CM, then go to the next step.
• Make sure to reconnect all disconnected (See 04-18-6 DSC/RSC HU/CM REMOVAL/
connectors. INSTALLATION.)
• Clear the DTC from the memory. No Go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS
[DSC/RSC].)
• Gradually slow down and stop the vehicle.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
No DTC troubleshooting completed.

End Of Sie

04-02–13
1890-1U-06H(04-02).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC C1115, C1185 [DSC/RSC]
id0402b3812000

Note
• Perform the inspection of DTCs other than C1115 and C1185 first when verifying DTCs.

DTC C1115, C1185 Valve relay system

• C1115
DETECTION — Short circuit in the DSC/RSC HU/CM internal value relay.
CONDITION • C1185
— Open circuit in the DSC/RSC HU/CM internal value relay.
POSSIBLE
• Open or short circuit in the DSC/RSC HU/CM internal valve relay, or stuck valve relay
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY DTC INSPECTION Yes Go to the applicable DTC inspection.
• Turn the ignition switch off. (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
• Using the M-MDS, perform the DTC No Go to the next step.
inspection.
• Are any DTCs other than C1115 and C1185
output?
2 VERIFY CURRENT STATUS OF Yes Replace the DSC/RSC HU/CM, then go to the next step.
MALFUNCTION (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Clear the DTC from the memory. INSTALLATION.)
(See 04-02-3 ON-BOARD DIAGNOSIS No Go to the next step.
[DSC/RSC].)
• Is the same DTC present?
3 VERIFY THAT NO DTCS ARE OUTPUT AGAIN Yes If DTC C1115 or C1185 is output again, replace the DSC/
• Drive the vehicle at 32km/h or more. RSC HU/CM.
• Stop the vehicle and verify the DTCs. (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Are DTCs output again? INSTALLATION.)
No DTC troubleshooting completed.

End Of Sie

04-02–14
1890-1U-06H(04-02).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC C1145, C1155, C1165, C1175 [DSC/RSC]
id0402b3801100

C1145 RF ABS wheel-speed sensor (open circuit) system

C1155 LF ABS wheel-speed sensor (open circuit) system
DTC
C1165 RR ABS wheel-speed sensor (open circuit) system
C1175 LR ABS wheel-speed sensor (open circuit) system
DETECTION • Open circuit has been detected in the ABS wheel-speed sensor or the ABS wheel-speed sensor wiring
CONDITION harness on any of the four vehicle wheels.
• Open circuit in the wiring harness between the following DSC/RSC HU/CM terminal and the ABS
wheel-speed sensor terminal:
— DSC/RSC HU/CM terminal AE—RF ABS wheel-speed sensor terminal A
— DSC/RSC HU/CM terminal AB—RF ABS wheel-speed sensor terminal B
— DSC/RSC HU/CM terminal AG—LF ABS wheel-speed sensor terminal A
POSSIBLE — DSC/RSC HU/CM terminal AD—LF ABS wheel-speed sensor terminal B
CAUSE — DSC/RSC HU/CM terminal G—RR ABS wheel-speed sensor terminal A
— DSC/RSC HU/CM terminal J—RR ABS wheel-speed sensor terminal B
— DSC/RSC HU/CM terminal F—LR ABS wheel-speed sensor terminal A 04-02
— DSC/RSC HU/CM terminal I—LR ABS wheel-speed sensor terminal B
• ABS wheel-speed sensor malfunction
• Poor connection at connectors (female terminal)

RF AE
A
ABS WHEEL-SPEED
SENSOR B AB

LF
A AG
ABS WHEEL-SPEED
SENSOR B AD
DSC/RSC HU/CM
RR
A G
ABS WHEEL-SPEED
SENSOR B J

LR
A F
ABS WHEEL-SPEED
B I
SENSOR
DSC/RSC HU/CM WIRING HARNESS-SIDE CONNECTOR

AK AH AE AB Y V S P M J G D B
AI AF AC Z W T Q N K H E

AL AJ AG AD AA X U R O L I F C A

ABS WHEEL-SPEED SENSOR WIRING HARNESS-SIDE CONNECTOR

FRONT REAR

B A B A

04-02–15
1890-1U-06H(04-02).fm 16 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PID TO VERIFY THAT WHEEL Yes Go to Step 4.
SPEED-SIGNALS ARE TRANSMITTED FROM No Go to the next step.
ABS WHEEL- SPEED SENSOR USING M-
MDS
• Turn the ignition switch off.
• Connect the M-MDS to the DLC-2.
• Select the following PIDs using the M-MDS:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Drive the vehicle.
• Verify that the wheel speed-signals are
transmitted from each ABS wheel-speed
sensor.
• Are the wheel-speed signals transmitted?
2 INSPECT FOR OPEN CIRCUIT IN WIRING Yes Go to the next step.
HARNESS BETWEEN DSC/RSC HU/CM AND No Repair or replace the wiring harness, then go to the next
ABS WHEEL-SPEED SENSOR step.
• Turn the ignition switch off.
• Disconnect the DSC/RSC HU/CM connector
and ABS wheel-speed sensor.
• Inspect for continuity in the wiring harness
between the following ABS wheel-speed
sensor connectors on the vehicle wiring
harness-side and DSC/RSC HU/CM
connectors.
— RF ABS wheel-speed sensor: AE—A
— RF ABS wheel-speed sensor: AB—B
— LF ABS wheel-speed sensor: AG—A
— LF ABS wheel-speed sensor: AD—B
— RR ABS wheel-speed sensor: G—A
— RR ABS wheel-speed sensor: J—B
— LR ABS wheel-speed sensor: F—A
— LR ABS wheel-speed sensor: I—B
• Is there continuity?
3 INSPECT ABS WHEEL-SPEED SENSOR FOR Yes Replace the ABS wheel-speed sensor, then go to the next
MALFUNCTION step.
• Turn the ignition switch off. (See 04-18-11 FRONT ABS WHEEL-SPEED SENSOR
• Disconnect the ABS wheel-speed sensor REMOVAL/INSTALLATION.)
connector which may have a malfunction. (See 04-18-13 REAR ABS WHEEL-SPEED SENSOR
• Turn the ignition switch to the ON position. REMOVAL/INSTALLATION [2WD].)
(engine off) (See 04-18-14 REAR ABS WHEEL-SPEED SENSOR
• Measure the power supply voltage between REMOVAL/INSTALLATION [AWD].)
the ABS wheel-speed sensor connector No Go to the next step.
terminal A (vehicle wiring harness-side) and
body ground on the ABS wheel-speed
sensor which may have a malfunction.
• Is the power supply voltage of the ABS
wheel-speed sensor which may have a
malfunction more than 10 V?
4 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the DSC/RSC HU/CM,
• Clear the DTCs from the memory. then go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS (See 04-18-6 DSC/RSC HU/CM REMOVAL/
[DSC/RSC].) INSTALLATION.)
• Are the same DTCs present? No Go to the next step.
5 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
• Are any other DTCs output? No DTC troubleshooting completed.

End Of Sie

04-02–16
1890-1U-06H(04-02).fm 17 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254, C1404, C1410, C1957, C1958 [DSC/RSC]
id0402b3814000

C 1194 LF outlet solenoid valve system

C 1198 LF inlet solenoid valve system
C 1210 RF outlet solenoid valve system
C 1214 RF inlet solenoid valve system
C 1242 LR outlet solenoid valve system
C 1246 RR outlet solenoid valve system
DTC
C 1250 LR inlet solenoid valve system
C 1254 RR inlet solenoid valve system
C 1404 RH traction control solenoid valve system
C 1410 LH traction control solenoid valve system
C 1957 RH stability control solenoid valve system
C 1958 LH stability control solenoid valve system
DETECTION • Solenoid valve operation does not correspond to solenoid ON/OFF commands from the DSC/RSC HU/
CONDITION CM.
04-02
• Open or short circuit in the DSC/RSC HU/CM internal solenoid valves
POSSIBLE
• Solenoid valve malfunction
CAUSE
• Poor connection at connectors (female terminal)

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY DTC INSPECTION Yes Go to the next step.
• Turn the ignition switch off. No Replace the DSC/RSC HU/CM, then go to the Step 3.
• Connect the M-MDS to the DLC-2. (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Turn the ignition switch to the ON position INSTALLATION.)
(engine off).
• Clear the DTC from the memory.
(See 04-02-3 ON-BOARD DIAGNOSIS
[DSC/RSC].)
• Re-perform the DTC inspection.
• Is more than one solenoid valve-related DTC
output?
2 INSPECT DSC/RSC HU/CM POWER SUPPLY Yes Replace the DSC/RSC HU/CM, then go to the next step.
AND GROUND CIRCUIT FOR OPEN CIRCUIT (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Measure the voltage between DSC/RSC HU/ INSTALLATION.)
CM terminal AL and terminal A. No Repair or replace the wiring harness, then go to the next
• Is the voltage more than 10 V? step.
3 VERIFY DTC TROUBLESHOOTING Yes Repeat the inspection from Step 1.
COMPLETED If the malfunction recurs, replace the DSC/RSC HU/CM,
• Clear the DTC from the memory. then go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS (See 04-18-6 DSC/RSC HU/CM REMOVAL/
[DSC/RSC].) INSTALLATION.)
• Are the same DTCs present? No Go to the next step.
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
No DTC troubleshooting completed.

End Of Sie

04-02–17
1890-1U-06H(04-02).fm 18 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC C1222 [DSC/RSC]
id0402b3801500

DTC C1222 ABS wheel-speed sensor system

DETECTION
• When the difference in the wheel speed between one tire and the others exceeds 25%.
CONDITION
POSSIBLE • A tire of different diameter is installed.
CAUSE • An incorrect ABS sensor rotor is installed (different number of teeth).

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PID (WHEEL SPEED) FOR Yes Go to Step 4.
DIFFERENCE IN EACH WHEEL SPEED No Go to the next step.
USING M-MDS
• Turn the ignition switch off.
• Connect the M-MDS to the DLC-2.
• Select the following PIDs using the M-MDS:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Drive the vehicle.
• Verify that the wheel speeds detected by the
four ABS wheel speed sensors are
approximately the same.
• Are the wheel speeds approximately the
same?
2 INSPECT THE SIZE OF THE TIRE THAT HAS Yes Go to the next step.
A DIFFERENT WHEEL SPEED No Replace the tire, then go to Step 4.
• Inspect the tire for differences in the tire
diameter caused by the tire size, wear, or tire
pressure.
• Is the tire diameter the same as the others?
3 INSPECT FOR INCORRECT ABS SENSOR Yes Go to the next step.
ROTOR INSTALLATION No Replace the ABS sensor rotor, then go to the next step.
• Inspect if the number of teeth on the ABS (See 04-18-11 FRONT ABS WHEEL-SPEED SENSOR
sensor rotor is incorrect. REMOVAL/INSTALLATION.)
• Is the number of teeth correct? (See 04-18-13 REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [2WD].)
(See 04-18-14 REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [AWD].)
4 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the DSC/RSC HU/CM,
• Clear the DTC from the memory. then go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS (See 04-18-6 DSC/RSC HU/CM REMOVAL/
[DSC/RSC].) INSTALLATION.)
• Are the same DTCs present? No Go to the next step.
5 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
• Are any other DTCs output? No DTC troubleshooting completed.

End Of Sie

04-02–18
1890-1U-06H(04-02).fm 19 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC C1233, C1234, C1235, C1236 [DSC/RSC]
id0402b3801600

C1233 LF ABS wheel-speed sensor/ABS sensor rotor system

C1234 RF ABS wheel-speed sensor/ABS sensor rotor system
DTC
C1235 RR ABS wheel-speed sensor/ABS sensor rotor system
C1236 LR ABS wheel-speed sensor/ABS sensor rotor system
• Vehicle wheel speed signals of any of the four vehicle wheels indicate abnormal acceleration that
DETECTION
exceeds specification.
CONDITION
• Periodic abnormality is detected in the signal wave pattern from the ABS wheel-speed sensors.
• ABS wheel-speed sensor malfunction (low output, metal shavings on sensor)
POSSIBLE • ABS sensor rotor malfunction (chipping of sensor rotor teeth)
CAUSE • Poor installation of ABS wheel-speed sensor and/or sensor rotor
• Excessive clearance between the ABS wheel-speed sensor and sensor rotor

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PID FOR ABNORMAL OUTPUT Yes Go to Step 4.
04-02
FROM ABS WHEEL-SPEED SENSOR USING No If there is a difference in speeds of the four wheels, go to the
M-MDS next step.
• Turn the ignition switch off.
• Connect the M-MDS to the DLC-2.
• Select the following PIDs using the M-MDS:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Start the engine and drive the vehicle.
• Verify that the PIDs of the four ABS wheel-
speed sensors correspond approximately.
• Do the vehicle speeds correspond?
2 INSPECT IF MALFUNCTION OCCURRED Yes Go to the next step.
DUE TO IMPROPER SENSOR CLEARANCE. No Replace the ABS wheel-speed sensor, then go to Step 4.
• Inspect the clearance between the ABS (See 04-18-11 FRONT ABS WHEEL-SPEED SENSOR
wheel-speed sensor and the ABS sensor REMOVAL/INSTALLATION.)
rotor. (See 04-18-13 REAR ABS WHEEL-SPEED SENSOR
(See 04-18-12 FRONT ABS WHEEL- REMOVAL/INSTALLATION [2WD].)
SPEED SENSOR INSPECTION.) (See 04-18-14 REAR ABS WHEEL-SPEED SENSOR
(See 04-18-14 REAR ABS WHEEL-SPEED REMOVAL/INSTALLATION [AWD].)
SENSOR INSPECTION [2WD].)
(See 04-18-15 REAR ABS WHEEL-SPEED
SENSOR INSPECTION [AWD].)
• Is the clearance normal?
Clearance
Front: 0.7—1.5 mm {0.028—0.059 in}
Rear (2WD): 0.3—1.1 mm {0.012—
0.043 in}
Rear (AWD): 0.95—1.75 mm {0.038—
0.068 in}
3 VISUALLY INSPECT ABS SENSOR ROTOR Yes Go to the next step.
FOR FOREIGN MATERIAL ADHERING OR No Replace the front drive shaft, rear wheel hub component
IMPROPER INSTALLATION (2WD) or rear drive shaft (AWD), then go to the next step.
• Is the result normal? (See 03-13-14 FRONT DRIVE SHAFT REMOVAL/
INSTALLATION.)
(See 03-12-3 WHEEL HUB COMPONENT REMOVAL/
INSTALLATION [2WD].)
(See 03-13-22 REAR DRIVE SHAFT REMOVAL/
INSTALLATION.)
4 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the DSC/RSC HU/CM,
• Clear the DTC from the memory. then go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS (See 04-18-6 DSC/RSC HU/CM REMOVAL/
[DSC/RSC].) INSTALLATION.)
• Start the engine and drive the vehicle at 10 No Go to the next step.
km/h {6.2 mph} or more.
• Are the same DTCs present?
5 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
• Are any other DTCs output? No DTC troubleshooting completed.

04-02–19
1890-1U-06H(04-02).fm 20 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

End Of Sie

DTC C1278, C1295, U2023 [DSC/RSC]

id0402b3815000

DTC C1278, C1295, U2023 Steering angle sensor system

• C1278
DETECTION — The steering angle sensor detects an abnormality in the signal.
CONDITION • C1295, U2023
— The steering angle sensor detects an internal abnormality.
POSSIBLE • Steering angle sensor malfunction
CAUSE • Poor connection at connectors (female terminal)

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT FOR BCM MALFUNCTION Yes Go to applicable DTC inspection.
• Turn the ignition switch off. (See 09-02K-2 DTC TABLE [BCM].)
• Using the M-MDS, perform the DTC No Go to the next step.
inspection for the BCM.
• Are any DTCs detected?
2 VERIFY DTC TROUBLESHOOTING Yes Replace the DSC/RSC HU/CM, then go to the next step.
COMPLETED (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Clear the DTC from the memory. INSTALLATION.)
(See 04-02-3 ON-BOARD DIAGNOSIS No Go to the next step.
[DSC/RSC].)
• Are the same DTCs present?
3 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
No DTC troubleshooting completed.

End Of Sie
DTC C1288 [DSC/RSC]
id0402b3811400

DTC C1288 Brake fluid pressure sensor system

DETECTION
• The pressure from the brake fluid pressure sensor when the system starts up is not within specification.
CONDITION
• Open or short circuit in the brake fluid pressure sensor circuit in the DSC/RSC HU/CM
POSSIBLE
• Malfunction in the brake fluid pressure sensor
CAUSE
• Conventional brake system malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT CONVENTIONAL BRAKE SYSTEM Yes Go to the next step.
• Inspect the conventional brake system for the No Replace the malfunctioning part, then go to the next step.
following:
— Normal master cylinder operation
— Brake fluid leakage between the master
cylinder and DSC/RSC HU/CM
— Normal brake switch operation
• Is the conventional brake system normal?
2 INSPECT BRAKE FLUID PRESSURE Yes Go to the next step.
SENSOR No Replace the DSC/RSC HU/CM, then go to the next step.
• Inspect the brake fluid pressure sensor. (See 04-18-6 DSC/RSC HU/CM REMOVAL/
(See 04-18-19 BRAKE FLUID PRESSURE INSTALLATION.)
SENSOR INSPECTION.)
• Is the brake fluid pressure sensor normal?
3 VERIFY NO ABNORMALITY ON BRAKE Yes Replace the DSC/RSC HU/CM, then go to the next step.
FLUID PRESSURE SENSOR (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Clear the DTCs from the memory. INSTALLATION.)
(See 04-02-3 ON-BOARD DIAGNOSIS No Go to the next step.
[DSC/RSC].)
• Are the same DTCs present?
4 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
• Are any other DTCs output? No DTC troubleshooting completed.

End Of Sie

04-02–20
1890-1U-06H(04-02).fm 21 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC C1327 [DSC/RSC]
id0402b3811500

DTC C1327 Brake fluid level sensor

DETECTION
• Brake fluid level remains low
CONDITION
POSSIBLE • Decrease in amount of brake fluid
CAUSE • Malfunction of brake fluid level sensor

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT FOR BCM MALFUNCTIONFOR Yes Go to applicable DTC inspection.
DTCs (See 09-02K-2 DTC TABLE [BCM])
• Turn the ignition switch off. No Go to the next step.
• Using the M-MDS, perform the DTC
inspection for the BCM.
• Are any DTCs detected? 04-02
2 INSPECT BRAKE FLUID LEVEL Yes Go to the next step.
• Inspect the brake fluid level. No Add brake fluid to specified level, then go to the next step.
• Is it normal?
3 INSPECT BRAKE FLUID LEVEL SENSOR Yes Go to the next step.
• Inspect the brake fluid level sensor. No Repair brake fluid level sensor, then go to the next step.
(See 04-11-9 BRAKE FLUID LEVEL (See 04-11-8 MASTER CYLINDER REMOVAL/
SENSOR INSPECTION.) INSTALLATION.)
• Is it normal?
4 VERIFY DTC TROUBLESHOOTING Yes Repeat the inspection from Step 1.
COMPLETED If the malfunction occurs again, replace the DSC/RSC HU/
• Clear the DTC from the memory. CM, then go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS (See 04-18-6 DSC/RSC HU/CM REMOVAL/
[DSC/RSC].) INSTALLATION.)
• Is the same DTC present? No Go to next step.
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
No DTC troubleshooting completed.

End Of Sie
DTC C1329, C1330, C1331, C1332, C1333, C1334, C1335, C1336, C1527, C1528, C1530, C1531 [DSC/RSC]
id0402b3811600

C 1329 RF outlet solenoid valve coil system

C 1330 LR outlet solenoid valve coil system
C 1331 RR outlet solenoid valve coil system
C 1332 LF outlet solenoid valve coil system
C 1333 LR inlet solenoid valve coil system
C 1334 LF inlet solenoid valve coil system
DTC
C 1335 RF inlet solenoid valve coil system
C 1336 RR inlet solenoid valve coil system
C 1527 RH traction control solenoid valve coil system
C 1528 LH traction control solenoid valve coil system
C 1530 RH stability control solenoid valve coil system
C 1531 LH stability control solenoid valve coil system
DETECTION
• Temperature of a solenoid valve coil exceeds specification.
CONDITION
POSSIBLE • This does not indicate a malfunction since constant control over extended period of time is inhibited to
CAUSE protect the RSC solenoid valve inside the DSC/RSC HU.

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY DTC TROUBLESHOOTING Yes Replace the DSC/RSC HU/CM, then go to the next step.
COMPLETED (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Clear the DTC from the memory. INSTALLATION.)
(See 04-02-3 ON-BOARD DIAGNOSIS No Go to the next step.
[DSC/RSC].)
• Are the same DTCs present?
2 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
No DTC troubleshooting completed.

04-02–21
1890-1U-06H(04-02).fm 22 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

End Of Sie

DTC C1446 [DSC/RSC]

id0402b3803400

DTC C1446 Brake switch system

• Brake switch ON signal is not input when the brake fluid pressure sensor signal reaches the specified
DETECTION value.
CONDITION • Brake switch ON signal is input even if the signal from the brake fluid pressure sensor is less than the
specification.
• Open or short circuit in wiring harness between the brake switch and PCM 1T terminal
POSSIBLE
• Brake switch malfunction
CAUSE
• Poor connection at connectors (female terminal)

BRAKE SWITCH
PCM 1T D A

1BJ 1BL
BRAKE LIGHT
CAN_L CAN_H

V Y

DSC/RSC HU/CM

DSC/RSC HU/CM WIRING HARNESS-SIDE CONNECTOR BRAKE SWITCH WIRING

HARNESS-SIDE CONNECTOR

AK AH AE AB Y V S P M J G D B D C B A
AI AF AC Z W T Q N K H E

AL AJ AG AD AA X U R O L I F C A

PCM WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C

1BR 1BM 1BH 1BD 1AZ 1AV 1AR AN1 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

04-02–22
1890-1U-06H(04-02).fm 23 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY OPEN OR SHORT CIRCUIT IN BRAKE Yes Go to Step 5.
SWITCH SIGNAL No If it is B+ under any condition, then go to the next
• Turn the ignition switch to the ON position. step.
• Measure the voltage between the PCM terminal 1T If it is 1 V or less under any condition, then go to
and body ground when the brake pedal is Step 3.
depressed and released:
Voltage
Brake pedal depressed: B+
Brake pedal released:
1 V or less
2 INSPECT BRAKE SWITCH SIGNAL FOR SHORT TO Yes Go to Step 4.
POWER SUPPLY CIRCUIT No Repair or replace the wiring harness between the
• Disconnect the brake switch connector. PCM and brake switch, then go to Step 5
• Measure the voltage between the brake switch 04-02
connector terminal D (vehicle harness-side) and
body ground.
• Is the voltage 1 V or less?
3 INSPECT BRAKE SWITCH SIGNAL FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the wiring harness between the
• Disconnect the PCM connectors. PCM and brake switch, then go to Step 5.
• Disconnect the brake switch connector.
• Inspect continuity between the PCM connector
terminal 1T (vehicle harness-side) and brake switch
terminal D:
• Is there continuity?
4 INSPECT BRAKE SWITCH Yes Go to the next step.
• Inspect the brake switch. No Replace the brake switch, then go to the next step.
(See 04-11-7 BRAKE SWITCH INSPECTION.) (See 04-11-4 BRAKE PEDAL REMOVAL/
• Is the brake switch normal? INSTALLATION.)
5 VERIFY THAT THE SAME DTC IS NOT PRESENT Yes Repeat the inspection from Step 1.
• Reconnect all disconnected connectors. If the malfunction recurs, replace the DSC/RSC HU/
• Clear the DTCs from the memory. CM, then go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS [DSC/ (See 04-18-6 DSC/RSC HU/CM REMOVAL/
RSC].) INSTALLATION.)
• Are the same DTCs present? No Go to the next step.
6 VERIFY THAT NO OTHER DTCS ARE PRESENT Yes Go to the applicable DTC inspection.
• Are any other DTCs output? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/
RSC].)
No DTC troubleshooting completed.

End Of Sie

04-02–23
1890-1U-06H(04-02).fm 24 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

DTC C1963 [DSC/RSC]
id0402b3811900

Note
• The initial point of the combined sensor (yaw rate sensor part) is corrected based on the signals from
each sensor while the vehicle is driven straight, however, the correction cannot be performed if the vehicle
is continuously driven on a curve and DTC C1963 is detected.

DTC C1963 Combined sensor (Yaw rate sensor part) initial point correction error
DETECTION • When a difference occurs between the estimated yaw rate value which is calculated by each sensor
CONDITION and the yaw rate value which is detected by the combined sensor (yaw rate sensor part).
• It occurs since the initial point correction for the combined sensor (yaw rate sensor part) cannot be
POSSIBLE
performed due to the vehicle being continuously driven on a curve, and does not indicate an DSC/RSC
CAUSE
system malfunction.

Diagnostic procedure
STEP INSPECTION ACTION
1 PERFORM INITIALIZATION PROCEDURE After the initialization procedure for the combined sensor has been
• Perform the initialization procedure for the completed, go to the next step.
combined sensor.
(See 04-18-9 DSC/RSC SENSOR
INITIALIZATION PROCEDURE.)
2 VERIFY DTC TROUBLESHOOTING Yes Repeat the inspection from Step 1.
COMPLETED If the malfunction occurs again, replace theDSC/ RSC HU/
• Clear the DTC from the memory. CM, then go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS (See 04-18-6 DSC/RSC HU/CM REMOVAL/
[DSC/RSC].) INSTALLATION.)
• Start the engine and drive the vehicle at 72 No Go to the next step.
km/h {45 mph} or more.
• Is the same DTC present?
3 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
No DTC troubleshooting completed.

End Of Sie
DTC C1991 [DSC/RSC]
id0402b3811800

DTC C1991 DSC/RSC sensor (abnormal initialization) system

DETECTION
• The DSC/RSC sensor detects that the initialization procedure has not been performed.
CONDITION
POSSIBLE
• The initialization procedure for the DSC/RSC sensor has not been performed.
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY INITIALIZATION PROCEDURE. Yes Go to the next step.
• Has the DSC/RSC sensor initialization No Perform the DSC/RSC sensor initialization procedure, then
procedure been performed? go to the next step. (See 04-18-9 DSC/RSC SENSOR
INITIALIZATION PROCEDURE.)
2 VERIFY DTC TROUBLESHOOTING Yes Repeat the inspection from Step 1.
COMPLETED If the malfunction occurs again, replace the DSC/RSC HU/
• Clear the DTC from the memory. CM, then go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS (See 04-18-6 DSC/RSC HU/CM REMOVAL/
[DSC/RSC].) INSTALLATION.)
• Is the same DTC present? No Go to the next step.
3 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)
No DTC troubleshooting completed.

End Of Sie
DTC U1901 [DSC/RSC]
id0402b3811700

DTC U1901 Combined sensor system (CAN2 line malfunction)

DETECTION
• The signal from the combined sensor is not within specification.
CONDITION

04-02–24
1890-1U-06H(04-02).fm 25 ページ ２００６年１２月１９日　火曜日　午前１１時３３分

ON-BOARD DIAGNOSTIC [DSC/RSC]

• Open or short circuit in the CAN2_L wiring harness between combined sensor terminal C and DSC/
RSC HU/CM terminal M
• Open or short circuit in the CAN2_H wiring harness between combined sensor terminal D and DSC/
POSSIBLE
RSC HU/CM terminal P
CAUSE
• Combined sensor malfunction
• DSC/RSC HU/CM malfunction
• Poor connection at connectors (female terminal)

CAN2_L
C M
COMBINED SENSOR DSC/RSC HU/CM
D P
CAN2_H

COMBINED SENSOR DSC/RSC HU/CM WIRING HARNESS-SIDE CONNECTOR 04-02

WIRING HARNESS-SIDE CONNECTOR

AK AH AE AB Y V S P M J G D B
AI AF AC Z W T Q N K H E
F E D C B A
AL AJ AG AD AA X U R O L I F C A

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT COMBINED SENSOR SIGNAL (CAN2 Yes Go to the next step.
LINE) FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to Step
• Disconnect the DSC/RSC HU/CM connectors. 4.
• Disconnect the combined sensor connectors.
• Inspect for continuity between the DSC/RSC HU/CM
connectors (vehicle harness-side) and the following
combined sensor connector terminals (vehicle
harness-side):
— Combined sensor (CAN2_L): M—C
— Combined sensor (CAN2_H): P—D
• Is there continuity?
2 INSPECT COMBINED SENSOR SIGNAL (CAN2 Yes Repair or replace the wiring harness, then go to Step
LINE) FOR SHORT CIRCUIT 4.
• Inspect for continuity between the following DSC/ No Go to the next step.
RSC HU/CM connector terminals (vehicle harness-
side) and body ground:
— Combined sensor (CAN2_L): M
— Combined sensor (CAN2_H): P
• Is there continuity?
3 INSPECT THE COMBINED SENSOR Yes Go to the next step.
• Reconnect all disconnected connectors. No Replace the combined sensor, then go to the next
Inspect the combined sensor. step.
(See 04-18-17 COMBINED SENSOR (See 04-18-16 COMBINED SENSOR REMOVAL/
INSPECTION.) INSTALLATION.)
• Is the combined sensor normal?
4 VERIFY THAT THE SAME DTC IS NOT PRESENT Yes Repeat the inspection from Step 1.
• Clear the DTCs from the memory. If the malfunction recurs, replace the DSC/RSC HU/
(See 04-02-3 ON-BOARD DIAGNOSIS [DSC/ CM, then go to the next step.
RSC].) (See 04-18-6 DSC/RSC HU/CM REMOVAL/
• Are the same DTCs present? INSTALLATION.)
No Go to the next step.
5 VERIFY THAT NO OTHER DTCS ARE PRESENT Yes Go to the applicable DTC inspection.
• Are any other DTCs output? (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/
RSC].)
No DTC troubleshooting completed.

04-02–25
1890-1U-06H(04-03).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時３９分

SYMPTOM TROUBLESHOOTING [DSC/RSC]

04-03 SYMPTOM TROUBLESHOOTING [DSC/RSC]
SYSTEM WIRING DIAGRAM NO.3 THERE IS A MALFUNCTION
[DSC/RSC] . . . . . . . . . . . . . . . . . . . . . . 04-03–2 IN THE SYSTEM EVEN THOUGH
FOREWORD [DSC/RSC] . . . . . . . . . . . . 04-03–2 ABS WARNING LIGHT, BRAKE
PRECAUTION [DSC/RSC] . . . . . . . . . . . 04-03–3 SYSTEM WARNING LIGHT, DSC
Intermittent Concern INDICATOR LIGHT AND TCS OFF
Troubleshooting . . . . . . . . . . . . . . . . . 04-03–4 LIGHT DO NOT ILLUMINATE
SYMPTOM TROUBLESHOOTING [DSC/RSC] . . . . . . . . . . . . . . . . . . . . . . . 04-03–9
[DSC/RSC] . . . . . . . . . . . . . . . . . . . . . . 04-03–5 NO.4 ABS OR TCS OPERATES
NO.1 ANY OF THE FOLLOWING FREQUENTLY/TCS DOES NOT
LIGHTS DO NOT ILLUMINATE WORK CORRECTLY
WHEN IGNITION SWITCH TURNED [DSC/RSC] . . . . . . . . . . . . . . . . . . . . . . . 04-03–9
TO ON POSITION: (ABS WARNING LIGHT, NO.5 DSC OPERATES
BRAKE SYSTEM WARNING LIGHT, FREQUENTLY/DSC DOES NOT WORK
DSC INDICATOR LIGHT AND/OR CORRECTLY [DSC/RSC]. . . . . . . . . . . . 04-03–10 04-03
TCS OFF LIGHT) [DSC/RSC] . . . . . . . . 04-03–7 NO.6 RSC OPERATES
NO.2 ANY OF THE FOLLOWING FREQUENTLY/RSC DOES NOT WORK
LIGHTS REMAIN ON: (ABS CORRECTRY [DSC/RSC] . . . . . . . . . . . 04-03–11
WARNING LIGHT, BRAKE SYSTEM
WARNING LIGHT, DSC INDICATOR
LIGHT AND/OR TCS OFF LIGHT)
[DSC/RSC] . . . . . . . . . . . . . . . . . . . . . . 04-03–8

End of Toc
WM: ROLL STABILITY CONTROL

04-03–1
1890-1U-06H(04-10).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時４０分

GENERAL PROCEDURES
04-10 GENERAL PROCEDURES
GENERAL PROCEDURES Brake Pipe Flare
(BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . 04-10–1 Nut Tightening. . . . . . . . . . . . . . . . . . . 04-10–1
Wheel and Tire Installation . . . . . . . . . 04-10–1 Connector Disconnection . . . . . . . . . . . 04-10–1
Brake Lines Disconnection. . . . . . . . . . 04-10–1 DSC/RSC Related Parts . . . . . . . . . . . . 04-10–1
DSC/RSC Related Part Sensor
Initialization Procedure . . . . . . . . . . . . 04-10–1

End of Toc
GENERAL PROCEDURES (BRAKE)
WM: BRAKES

id041000800100
Wheel and Tire Installation
1. When installing the wheels and tires, tighten the
wheel nuts in a criss-cross pattern to the following 04-10
tightening torque.

Tightening torque 1
107.8—147.0 N·m {11.0—14.9 Kgf·m, 79.6— 4 3
108.4 ft·lbf}
2 5

acxuuw00000002

Brake Lines Disconnection

1. If any brake line has been disconnected during the procedures, add brake fluid, bleed the brakes, and inspect
for leakage after the procedure has been completed.

Caution
• Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is
spilled, wipe it off immediately.

Brake Pipe Flare Nut Tightening

1. Tighten the brake pipe flare nut using the commercially available flare nut wrench.

Connector Disconnection
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)

DSC/RSC Related Parts

1. Make sure that there are no DTCs in the DSC/RSC memory after working on DSC/RSC related parts. If there
are any DTCs in the memory, clear them. (See 04-02-3 ON-BOARD DIAGNOSIS [DSC/RSC].)

DSC/RSC Related Part Sensor Initialization Procedure

Warning
• If the initialization procedure is not completed, the DSC/RSC will not operate properly and it might
cause an unexpected accident. Therefore, when replacing or removing the following parts, make
sure to perform the initialization procedure to insure proper RSC operation.

1. When replacing or removing the following parts, perform the initialization procedure. (See 04-18-9 DSC/RSC
SENSOR INITIALIZATION PROCEDURE.)
• DSC/RSC HU/CM
• Combined sensor
End Of Sie

04-10–1
1890-1U-06H(04-11).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

04-11 CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE SYSTEM Brake Judder Repair Hint . . . . . . . . . . . 04-11–12
LOCATION INDEX. . . . . . . . . . . . . . . . . 04-11–2 Disc Plate Thickness Inspection . . . . . . 04-11–14
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . 04-11–3 Disc Pad Thickness Inspection . . . . . . . 04-11–14
BRAKE PEDAL INSPECTION . . . . . . . . 04-11–3 FRONT BRAKE (DISC)
Pedal Height Inspection . . . . . . . . . . . . 04-11–3 REMOVAL/INSTALLATION . . . . . . . . . . 04-11–15
Pedal Play Inspection. . . . . . . . . . . . . . 04-11–4 Caliper Installation Note . . . . . . . . . . . . 04-11–15
Pedal-to-floor DISC PAD (FRONT)
Clearance Inspection . . . . . . . . . . . . . 04-11–4 REPLACEMENT . . . . . . . . . . . . . . . . . . . 04-11–16
BRAKE PEDAL CALIPER (FRONT)
REMOVAL/INSTALLATION. . . . . . . . . . 04-11–4 DISASSEMBLY/ASSEMBLY . . . . . . . . . 04-11–16
Brake Pedal Removal Note . . . . . . . . . 04-11–5 Piston Disassembly Note . . . . . . . . . . . 04-11–17
Brake Switch Installation Note . . . . . . . 04-11–7 REAR BRAKE (DISC)
Brake Switch Connector INSPECTION . . . . . . . . . . . . . . . . . . . . . 04-11–17
Installation Note . . . . . . . . . . . . . . . . . 04-11–7 Brake Judder Repair Hint . . . . . . . . . . . 04-11–17 04-11
BRAKE SWITCH INSPECTION . . . . . . . 04-11–7 Disc Plate Thickness Inspection . . . . . . 04-11–19
MASTER CYLINDER Disc Pad Thickness Inspection . . . . . . . 04-11–19
REMOVAL/INSTALLATION. . . . . . . . . . 04-11–8 REAR BRAKE (DISC)
BRAKE FLUID LEVEL REMOVAL/INSTALLATION . . . . . . . . . . 04-11–20
SENSOR INSPECTION . . . . . . . . . . . . . 04-11–9 Disc Plate Removal Note . . . . . . . . . . . 04-11–21
POWER BRAKE UNIT Disc Plate, Screw
INSPECTION . . . . . . . . . . . . . . . . . . . . . 04-11–9 Installation Note . . . . . . . . . . . . . . . . . 04-11–21
Without Using SST. . . . . . . . . . . . . . . . 04-11–9 Caliper Installation Note . . . . . . . . . . . . 04-11–22
Using SST . . . . . . . . . . . . . . . . . . . . . . 04-11–9 DISC PAD (REAR)
POWER BRAKE UNIT REPLACEMENT . . . . . . . . . . . . . . . . . . . 04-11–22
REMOVAL/INSTALLATION. . . . . . . . . . 04-11–11 CALIPER (REAR)
FRONT BRAKE (DISC) DISASSEMBLY/ASSEMBLY . . . . . . . . . 04-11–23
INSPECTION . . . . . . . . . . . . . . . . . . . . . 04-11–12 Piston Disassembly Note . . . . . . . . . . . 04-11–23

End of Toc
WM: BRAKES

04-11–1
1890-1U-06H(04-11).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

CONVENTIONAL BRAKE SYSTEM LOCATION INDEX
id041100800100

2WD

4 5
6
1

7 AWD

ac9uuw00002284

1 Brake fluid reserve tank 7 Front brake (disc)

(See 04-11-3 AIR BLEEDING.) (See 04-11-12 FRONT BRAKE (DISC)
2 Brake pedal INSPECTION.)
(See 04-11-3 BRAKE PEDAL INSPECTION.) (See 04-11-15 FRONT BRAKE (DISC) REMOVAL/
(See 04-11-4 BRAKE PEDAL REMOVAL/ INSTALLATION.)
INSTALLATION.) (See 04-11-16 DISC PAD (FRONT)
REPLACEMENT.)
3 Brake switch (See 04-11-16 CALIPER (FRONT) DISASSEMBLY/
(See 04-11-7 BRAKE SWITCH INSPECTION.) ASSEMBLY.)
4 Master cylinder 8 Rear brake (disc)
(See 04-11-8 MASTER CYLINDER REMOVAL/ (See 04-11-17 REAR BRAKE (DISC)
INSTALLATION.) INSPECTION.)
5 Brake fluid level sensor (See 04-11-20 REAR BRAKE (DISC) REMOVAL/
(See 04-11-9 BRAKE FLUID LEVEL SENSOR INSTALLATION.)
INSPECTION.) (See 04-11-22 DISC PAD (REAR)
6 Power brake unit REPLACEMENT.)
(See 04-11-9 POWER BRAKE UNIT INSPECTION.) (See 04-11-23 CALIPER (REAR) DISASSEMBLY/
(See 04-11-11 POWER BRAKE UNIT REMOVAL/ ASSEMBLY.)
INSTALLATION.)

04-11–2
1890-1U-06H(04-11).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

End Of Sie

AIR BLEEDING
WM: CONVENTIONAL BRAKE SYSTEM

id041100800200

Caution
• Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is
spilled, wipe it off immediately.

Note
• Keep the fluid level in the reserve tank at 3/4 full or more during the air bleeding.
• Begin air bleeding with the brake caliper that is furthest from the master cylinder.

Brake fluid type

SAE J1703, FMVSS 116 DOT-3

1. Remove the bleeder cap on the brake caliper, and attach a vinyl tube to the bleeder screw.
2. Place the other end of the vinyl tube in a clear container and fill the container with fluid during air bleeding.
04-11
3. Working with two people, one should pump the brake pedal several times and depress and hold the pedal
down.
4. While the brake pedal is depressed, the other
should loosen the bleeder screw using a
commercially available flare nut wrench, drain out
any fluid containing air bubbles, and tighten the
bleeder screw.

Tightening torque
Front: 5.9—9.8 N·m {61—99 kgf·cm, 53—86
in·lbf}
Rear: 6.9—9.8 N·m {71—99 kgf·cm, 61—86
in·lbf}
ac9uuw00001441
5. Repeat Steps 3 and 4 until no air bubbles are
seen.
6. Perform air bleeding as described in the above procedures for all brake calipers.
7. After air bleeding, inspect the following:
• Brake operation
• Fluid leakage
• Fluid level
End Of Sie
BRAKE PEDAL INSPECTION
WM: BRAKE PEDAL

id041100801100
Pedal Height Inspection
1. Measure the distance from the center of the
upper surface of the pedal pad to the insulator
and verify that it is as specified.
• If not within the specification, inspect the
following items and repair or replace the
applicable part if there is any malfunction.
— Power brake unit installation condition
— Deformation of or damage to the power
brake unit fork
— Brake pedal installation condition
— Clevis pin wear
• If there is no malfunction in the above items,
replace the brake pedal.
INSULATOR
Brake pedal height (reference value)
206.3 mm {8.122 in}

PEDAL HEIGHT

ac9uuw00002281

04-11–3
1890-1U-06H(04-11).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

Pedal Play Inspection
1. Pump the pedal several times to release the vacuum in the power brake unit.
2. Gently depress the pedal by hand and measure the pedal play.
• If not within the specification, inspect the wear of the clevis pin. Replace it if there is any malfunction.

Brake pedal play

2—5 mm {0.08—0.19 in}

Note
• If there is no malfunction in the clevis pin, there is a possibility that the power brake unit has some
malfunction. Verify that there are no malfunctions, and replace it if necessary.

Pedal-to-floor Clearance Inspection

1. Start the engine and depress the brake pedal with a force of 147 N {15.0 kgf, 33.0 lbf}.
2. Measure the distance from the center of the
upper surface of the pedal pad to the floor
covering and verify that it is as specified.
• If it is less than the specification, inspect for
air in the brake line.

Brake pedal-to-floor clearance (Brake pedal

when depressed at 147 N {15.0 kgf, 33.0
lbf})
97.6 mm {3.84 in} or more

End Of Sie

PEDAL-TO-FLOOR
CLEARANCE
FLOOR
COVERING

ac9uuw00002282

BRAKE PEDAL REMOVAL/INSTALLATION

id041100801200

Caution
• The clearance between the brake switch and the brake pedal is automatically adjusted to the
correct amount when the brake switch is inserted into the installation hole on the brake pedal and
rotated to fix in place. If the brake switch is not properly installed, the clearance may be incorrect,
causing a brake light malfunction. Therefore, always verify that the brake pedal is properly
installed and fully released before installing the brake switch to the pedal.
• Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again.
Therefore, replace the switch with a new one when replacing the power brake unit or the pedal, or
performing any procedure that changes the pedal stroke.

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

04-11–4
1890-1U-06H(04-11).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

6 8

5
A B

B
4
A

C
7
18.6—25.5
{1.90—2.60,
13.8—18.8}
04-11

9
R 2
1

3
C

N·m {kgf·m, ft·lbf}

ac9uuw00001463

1 Brake switch connector 4 Noise filter

(See 04-11-7 Brake Switch Connector Installation 5 Snap pin
Note.)
6 Clevis pin
2 Brake switch
(See 04-11-7 Brake Switch Installation Note.) 7 Nut
3 Interlock cable 8 Brake pedal
(See 05-18-3 INTERLOCK CABLE ADJUSTMENT.) (See 04-11-5 Brake Pedal Removal Note.)
9 Pedal pad

Brake Pedal Removal Note

1. Remove the windshield wiper arm and blade. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION.)
2. Remove the cowl grille. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
3. Remove the windshield wiper motor. (See 09-19-4 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
4. Remove the cowl panel. (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
5. Remove the decoration panel. (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
6. Remove the front console box mat. (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
7. Remove the indicator panel. (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
8. Remove the front console box. (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
9. Remove the dashboard under cover. (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
10. Remove the side wall. (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
11. Remove the console panel. (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
12. Remove the console cover. (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
13. Remove the console. (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
14. Remove the front scuff plate inner. (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
15. Remove the front side trim. (See 09-17-23 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
16. Remove the hood release lever. (See 09-14-46 HOOD LATCH AND RELEASE LEVER REMOVAL/
INSTALLATION.)
17. Remove the lower panel. (See 09-17-11 LOWER PANEL REMOVAL/INSTALLATION.)
18. Remove the Glove Compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)

04-11–5
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CONVENTIONAL BRAKE SYSTEM

19. Remove the a-pillar trim. (See 09-17-19 A-PILLAR TRIM REMOVAL/INSTALLATION.)
20. Remove the dashboard installation bolts as shown in the figure.

Caution
• Bolt A cannot be removed from the body. For this reason, a front door obstructed by the bolt when
the door is opened could cause it to be scratched. When opening a front door, verify that bolt A is
inserted.

15.7—22.5
{1.61—2.29,
11.5—16.3}

15.7—22.5
{1.61—2.29,
11.5—16.3}

15.7—22.5
BOLT A {1.61—2.29,
11.5—16.3}

15.7—22.5 18.6—25.5
{1.61—2.29, {1.90—2.60,
11.5—16.3} 13.8—18.8}

N·m {kgf·m, ft·lbf}

ac9uuw00001483

21. Lift the dashboard upward and move it 20 mm {0.78 in} to the rear of the vehicle after the locator pin for the
dashboard member is in the position shown in the figure.

20 mm {0.78 in} DASHBOARD MEMBER

DASHBOARD

LOCATOR PIN

LOCATOR PIN

20 mm {0.78 in}

LOCATOR PIN

ac9uuw00001464

04-11–6
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CONVENTIONAL BRAKE SYSTEM

Caution
• If the dashboard is moved towards the vehicle rear excessively, the wiring harness could be
damaged. Mark the position and verify the distance when moving the dashboard.

Note
• When verifying the position of the dashboard
member, verify visually with the locator pin
from the underside of the dashboard.

22. Move the power brake unit to the vehicle front

where the power brake unit fork does not interfere
with the brake pedal arm. DASHBOARD
23. Remove the brake pedal. MEMBER

04-11
LOCATOR PIN
ac9uuw00001465

Brake Switch Installation Note

1. Inspect the brake pedal. (See 04-11-3 BRAKE PEDAL INSPECTION.)
2. With the brake pedal fully released, insert a new brake switch into the installation hole on the lock unit.
3. Secure the brake switch by turning it clockwise
45°. 45°

BRAKE SWITCH

LOCK UNIT
ac9uuw00001487

Brake Switch Connector Installation Note

1. Inspect the brake pedal. (See 04-11-4 BRAKE PEDAL REMOVAL/INSTALLATION.)
2. With the brake pedal in its original position, install the brake switch to the brake switch connector.
End Of Sie
BRAKE SWITCH INSPECTION
WM: BRAKE SWITCH

id041100801900

Caution
• Inspect the brake switch with it installed to the brake pedal, otherwise the brake switch may not
operate normally. If the brake switch is removed from the brake pedal, replace the brake switch
with a new one.

1. Disconnect the brake switch connector.

2. Verify that the continuity is as indicated in the
table.
• If not as indicated in the table, replace the
brake switch. C A
D B
: Continuity
Terminal
Condition
A B C D
When the brake pedal
is depressed

ac9uuw00001420
When the brake pedal
is not depressed
ac9uuw00001421
End Of Sie
WM: MASTER CYLINDER

04-11–7
1890-1U-06H(04-11).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

MASTER CYLINDER REMOVAL/INSTALLATION
id041100801300
1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the resonance chamber. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the bolt and nut as shown in the figure,
and move the vacuum pipe bracket.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal. VACUUM PIPE
BRACKET 21—25 N·m
{2.2—2.5 kgf·m,
16—18 ft·lbf}

7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}

ac9uuw00002061

6. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See 04-11-3 AIR BLEEDING.)

B
R 6 A
5
1
B

2
20—30 {2.1—3.0, 15—22}

R
21—25 {2.2—2.5, 16—18}
N·m {kgf·m, ft·lbf}
ac9uuw00001924

1 Brake fluid level sensor connector 4 Reserve tank

2 Brake pipe 5 Master cylinder
3 Master cylinder component 6 O-ring

End Of Sie

04-11–8
1890-1U-06H(04-11).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

BRAKE FLUID LEVEL SENSOR INSPECTION
id041100801400
1. Disconnect the brake fluid level sensor connector from the master cylinder.
2. Inspect for continuity according to fluid level
between the brake fluid level sensor terminals.
• If not as indicated in the table, replace the
No.1 reserve tank. (See 04-11-8 MASTER
CYLINDER REMOVAL/INSTALLATION.) C B A

: Continuity
Terminal
Condition
A B

Above MIN
ac9uuw00001418
Below MIN
04-11
ac9uuw00001419

End Of Sie
POWER BRAKE UNIT INSPECTION
WM: POWER BRAKE UNIT

id041100801700

Note
• The following inspection methods are simple inspection methods to judge the function of the power brake
unit.
• If there is any malfunction in the power brake unit, replace the power brake unit as a single unit.

Without Using SST

Operation inspection
1. With the engine stopped, pump the pedal a few times.
2. With the pedal depressed, start the engine.
3. If the pedal moves down slightly immediately after starting the engine, the unit is normal.

Vacuum function inspection

1. Start the engine.
2. Stop the engine after driving the vehicle for 1—2 min.
3. Depress the pedal with normal force.
4. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is normal.
• If a problem is found, inspect for damage to or improper installation of the check valve and vacuum hose.
After repairing, inspect again.

Vacuum loss function inspection

1. Start the engine.
2. Depress the pedal with normal force.
3. With the pedal depressed, stop the engine.
4. Hold the pedal depressed for approx. 30 s.
5. If the pedal height does not change during this time, the unit is normal.

Using SST
Pre-inspection preparation
1. Disconnect the brake pipe flare nut area using the
commercially available flare nut wrench as shown
in the figure. BRAKE PIPE
2. Remove the clamp and disconnect the brake CLAMP
hose.

BRAKE HOSE

ac9uuw00002283

04-11–9
1890-1U-06H(04-11).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

3. Install the SST to the brake pipe as shown in the
figure. 49 U043 004A
4. Bleed the brake line and the SSTs of air. Bleed
the air form the SSTs using bleeder screw A.
5. Install the pedal force gauge to the brake pedal.
6. Connect the vacuum gauge to the vacuum line. A 49 U043 006

49 U043 005
ac9uuw00001334

Vacuum loss inspection

1. Start the engine.
2. Depress the brake pedal with a force of 200 N {20.4 kgf, 44.9 lbf}.
3. Stop the engine when the vacuum gauge reading reaches 68 kPa {510 mmHg, 20.1 inHg} with the pedal
depressed.
4. With the engine off, observe the vacuum gauge for 15 s.
5. If the gauge has dropped 3.3 kPa {25 mmHg, 1.0 inHg} or less, the unit is normal.

Lack of hydraulic pressure inspection

1. If the pedal force and fluid pressure correlation is within the specification with the engine stopped and a vacuum
amount of 0 kPa {0 mmHg, 0 inHg}, the system is normal.

Master cylinder fluid pressure

Vacuum amount at o kPa {0 mmHg, 0 inHg}
Pedal force (N {kgf, lbf}) Fluid pressure (kPa {kgf/cm2, psi})
200 N {20.4kgf, 44.9lbt} 520 kPa {5.31 kgf/cm2, 75.5 psi} or more

Hydraulic pressure inspection

1. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa {500 mmHg, 19.7 inHg}.
2. At this time, apply the indicated pedal force and if the fluid pressure is within the specification, the unit is
normal.

Master cylinder fluid pressure

Vacuum amount at 66.7 kPa {500 mmHg, 19.7 inHg}
Pedal force (N {kgf, lbf}) Fluid pressure (kPa {kgf/cm2, psi})
200 N {20.4kgf, 44.9lbt} 9,000 kPa {91.78 kgf/cm2, 1,306 psi} or more

After-inspection procedure
1. After the inspection, remove the SSTs, install the
brake hose, clamp, and brake pipe to the original BRAKE PIPE
positions, and then bleed the air from the brake 12.8—21.6 N·m
line. {131—220 kgf·cm,
114—191 in·lbf}
End Of Sie

ac9uuw00002376

04-11–10
1890-1U-06H(04-11).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

POWER BRAKE UNIT REMOVAL/INSTALLATION
id041100801800
1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the resonance chamber. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove the windshield wiper arm and blade. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION.)
4. Remove the cowl grill. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
5. Remove the windshield wiper motor. (See 09-19-4 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
6. Remove the cowl panel. (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
7. Remove the master cylinder component. (See 04-11-8 MASTER CYLINDER REMOVAL/INSTALLATION.)
8. Remove the nuts as shown in the figure, and
move the front heater pipe.
9. Remove the brake pipe (DSC/RSC HU/CM—
master cylinder). (See 04-18-6 DSC/RSC HU/CM
REMOVAL/INSTALLATION.).

04-11

8—12 N·m
{82—122 kgf·cm,
71—106 in·lbf}
FRONT HEATER PIPE
ac9uuw00001268
10. Disconnect the brake pipe (DSC/RSC HU/CM
side) as shown in the figure. BRAKE PIPE
12.8—21.6 N·m
11. Remove in the order indicated in the table. {131—220 kgf·cm,
12. Install in the reverse order of removal. 114—191 in·lbf}
13. After installation, add brake fluid, bleed the air,
and inspect for fluid leakage. (See 04-11-3 AIR
BLEEDING.)

ac9uuw00001485
14. Inspect the brake pedal. (See 04-11-3 BRAKE PEDAL INSPECTION.)

R
B
2 5
4

18.6—25.5 N·m
B {1.90—2.60 kgf·m,
A 13.8—18.8 ft·lbf}

1
ac9uuw00001486
.

1 Vacuum hose 4 Power brake unit

2 Snap pin 5 Gasket
3 Clevis pin

04-11–11
1890-1U-06H(04-11).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

End Of Sie

FRONT BRAKE (DISC) INSPECTION

WM: FRONT BRAKE (DISC)

id041100800800
Brake Judder Repair Hint
Description
Brake judder concern has the following three characteristics:

Steering wheel vibration

Steering wheel vibrates in the direction of its rotation. This characteristic is most noticeable when applying brakes
at a vehicle speed of 100—140 km/h {62—87 mph}.

Floor vibration
When applying brakes, the vehicle body shakes back and forth. The seriousness of shake is not influenced by
vehicle speed.

Brake pedal vibration

When applying brakes, a pulsating force tries to push the brake pad back. The pulsation is transmitted to the brake
pedal.
The following are the main possible causes of brake judder:

Due to an excessive runout (side-to-side wobble) of disc plate, the thickness of disc plate is uneven.
If the runout is more than 0.05 mm {0.002 in} at the position 10 mm {0.39 in} from the disc plate edge, uneven
wear occurs on the disc plate because of uneven pad/plate contact.
If the runout is less than 0.05 mm {0.002 in}, uneven wear does not occur.

The disc plate is deformed by heat.

Repeated panic braking may raise the temperature in some portions of disc plate by approx. 1,000 °C {1,832 °F}.
This results in deformed disc plate.

Due to corrosion, the thickness and friction coefficient of disc plate change.
If a vehicle is parked under damp conditions for a long time, corrosion occurs on the friction surface of disc plate.
The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the friction
coefficient and causes a reaction force.

04-11–12
1890-1U-06H(04-11).fm 13 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

Inspection and repair procedure

,
Confirm customer s complaint

Perform lateral runout inspection. More than 0.05 mm {0.002 in}

(Refer to Lateral Runout Inspection.)
Less than Less than
0.05 mm 0.05 mm
{0.002 in} Occurs {0.002 in}
Verify whether brake Remove disc plate and
Does not judder occurs or not. reinstall in other phase.
occur Perform lateral runout
inspection again. 04-11
Perform thickness variation
inspection (Refer to the More than 0.015 mm {0.0005 in}
following.) More than
Less than 0.015 mm {0.0005 in} 0.05 mm
{0.002 in}
Confirm customer's complaint again.
Machine the disc plate using
Work is completed. on-the-car type lathe.

Secure the disc plate by

tightening all hub nuts to the
same torque, and measure lateral
runout.

On-the-car type lathe (less than

0.015 mm {0.0005 in}).

Work is completed.

ac9uuw00001427

Lateral runout inspection

1. To secure the disc plate and the hub, tighten the hub nuts upside down or insert a washer (thickness 10 mm
{0.39 in} with an inner diameter more than 12 mm {0.47 in}) between the hub bolt and the hub nut.

Note
• The component parts of the SST (49 B017 001 or 49 G019 003) can be used as a suitable washer.

2. After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of disc plate 10
mm {0.39 in} from the disc plate edge.
3. Rotate the disc plate one time and measure the runout.

Front disc plate runout limit

0.05 mm {0.002 in}

04-11–13
1890-1U-06H(04-11).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

Thickness variation inspection
1. Clean the disc plate-to-pad friction surface using a brake cleaner.
2. Measure the points indicated in the illustration using a caliper (micrometer).
3. Subtract the minimum value from the maximum.
• If the result is not within specification,
machine the disc plate using a lathe.

Thickness variation limit

0.015 mm {0.0005 in}

Warning
• Do not exceed minimum disc plate
thickness.

ac9uuw00001428

Disc Plate Thickness Inspection

Caution
• Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine
the disc plate while installed on the vehicle.

1. Measure the thickness of the disc plate.

• If the thickness is not within the specification, replace the disc plate.

Minimum front disc plate thickness

26 mm {1.03 in}

Minimum front disc plate thickness after machining using a brake lathe on-vehicle
26.8 mm {1.06 in}

Disc Pad Thickness Inspection

1. Jack up the front of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Verify the remaining thickness of the pad
s.
• Replace the pads as a set: right and left
wheels, if either one is at or less than the
minimum thickness.

Minimum front disc pad thickness

2.0 mm {0.08 in}

End Of Sie

ac9uuw00001429

04-11–14
1890-1U-06H(04-11).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

FRONT BRAKE (DISC) REMOVAL/INSTALLATION
id041100800900
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See 04-11-3 AIR BLEEDING.)
4. After installation, depress the brake pedal a few times, rotate the wheel by hand, and verify that the brake does
not drag.
107.8—127.4
{11.00—12.99,
83.3—93.1 79.51—93.96}
{8.50—9.49,
61.5—68.6} 8
21.6—29.4
2 {2.21—2.99,
SST 16.0—21.6}
3 12
1
D 04-11
GREASE

B
5 C
R
C 10 R
D

7
6 6 9.8—14.7 N·m 11
4 {100—149 kgf·cm,

GREASE
87—130 in·lbf}
GREASE

A 10 A
GREASE

A R 7 9 4
ANTI-RATTLE
GREASE

A
GREASE

GREASE

BRAKE GREASE
B A
GREASE

B RUBBER GREASE N·m {kgf·m, ft·lbf}

ac9uuw00001422

1 Brake hose 7 Guide plate

2 Slide pin bolt 8 Bolt
3 Caliper 9 Mounting support
(See 04-11-15 Caliper Installation Note.) 10 Dust boot
4 Disc pad 11 Screw
5 Pad wear indicator 12 Disc plate
6 Shim

Caliper Installation Note

1. Push the piston fully inward using the SST.
2. Install the caliper.
End Of Sie
WM: DISC PAD (FRONT)
WOOD PLATES
49 0221 600C

ac9uuw00001423

04-11–15
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CONVENTIONAL BRAKE SYSTEM

DISC PAD (FRONT) REPLACEMENT
id041100800700
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, depress the brake pedal a few times, rotate the wheel by hand, and verify that the brake does
not drag.

2 SST
GREASE

1
83.3—93.1
5 {8.50—9.49,
4 61.5—68.6}

6 A

GREASE

A
GREASE

ANTI-RATTLE 6
GREASE

BRAKE GREASE N·m {kgf·m, ft·lbf}

ac9uuw00001424

1 Slide pin bolt 3 Disc pad

2 Caliper 4 Pad wear indicator
(See 04-11-15 FRONT BRAKE (DISC) REMOVAL/ 5 Shim
INSTALLATION.)
6 Guide plate

End Of Sie
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY
WM: CALIPER (FRONT)

id041100801000
1. Disassemble in the order indicated in the table.
5.9—9.8 {61—99, 53—86}
1 Bleeder cap
1 2 6
2 Bleeder screw R BRAKE
FLUID

3 Piston 5 SST
(See 04-11-17 Piston Disassembly Note.)
3 R
4 Dust seal
4
5 Piston seal
6 Caliper

2. Assemble in the reverse order of removal.

GREASE

GREASE
GREASE

RUBBER GREASE
N·m {kgf·cm, in·lbf}

ac9uuw00001425

04-11–16
1890-1U-06H(04-11).fm 17 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

Piston Disassembly Note

Warning
• When compressed air is blown into the caliper body, injury to a finger or other part from pinching
could result from the piston springing up. When blowing in compressed air, do not place your
fingers between the piston and caliper body when performing the work.

Caution
• The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.

1. Place the SST in the caliper, then blow

compressed air through the hole to force the
piston out of the caliper. 49 T033 001A
End Of Sie
04-11
WM: REAR BRAKE (DISC)

ac9uuw00001426

REAR BRAKE (DISC) INSPECTION

id041100800400
Brake Judder Repair Hint
Description
Brake judder concern has the following three characteristics:

Steering wheel vibration

Steering wheel vibrates in the direction of its rotation. This characteristic is most noticeable when applying brakes
at a vehicle speed of 100—140 km/h {62—87 mph}.

Floor vibration
When applying brakes, the vehicle body shakes back and forth. The seriousness of shake is not influenced by
vehicle speed.

Brake pedal vibration

When applying brakes, a pulsating force tries to push the brake pad back. The pulsation is transmitted to the brake
pedal.
The following are the main possible causes of brake judder:

Due to an excessive runout (side-to-side wobble) of disc plate, the thickness of disc plate is uneven.
If the runout is more than 0.05 mm {0.002 in} at the position 10 mm {0.39 in} from the disc plate edge, uneven
wear occurs on the disc plate because of uneven pad/plate contact.
If the runout is less than 0.05 mm {0.002 in}, uneven wear does not occur.

The disc plate is deformed by heat.

Repeated panic braking may raise the temperature in some portions of disc plate by approx. 1,000 °C {1,832 °F}.
This results in deformed disc plate.

Due to corrosion, the thickness and friction coefficient of disc plate change.
If a vehicle is parked under damp conditions for a long time, corrosion occurs on the friction surface of disc plate.
The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the friction
coefficient and causes a reaction force.

04-11–17
1890-1U-06H(04-11).fm 18 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

Inspection and repair procedure

,
Confirm customer s complaint

Perform lateral runout inspection. More than 0.05 mm {0.002 in}

(Refer to Lateral Runout Inspection.)
Less than Less than
0.05 mm 0.05 mm
{0.002 in} Occurs {0.002 in}
Verify whether brake Remove disc plate and
Does not judder occurs or not. reinstall in other phase.
occur Perform lateral runout
Perform thickness variation inspection again.
inspection (Refer to the More than 0.015 mm {0.0005 in}
following.) More than
Less than 0.015 mm {0.0005 in} 0.05 mm
{0.002 in}
Confirm customer's complaint again.
Machine the disc plate using
Work is completed. on-the-car type lathe.

Secure the disc plate by

tightening all hub nuts to the
same torque, and measure lateral
runout.

On-the-car type lathe (less than

0.015 mm {0.0005 in}).

Work is completed.

ac9uuw00001430

Lateral runout inspection

1. To secure the disc plate and the hub, tighten the hub nuts upside down or insert a washer (thickness 10 mm
{0.39 in} with an inner diameter more than 12 mm {0.47 in}) between the hub bolt and the hub nut.

Note
• The component parts of the SST (49 B017 001 or 49 G019 003) can be used as a suitable washer.

2. After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of disc plate 10
mm {0.39 in} from the disc plate edge.
3. Rotate the disc plate one time and measure the runout.

Rear disc plate runout limit

0.05 mm {0.002 in}

04-11–18
1890-1U-06H(04-11).fm 19 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

Thickness variation inspection
1. Clean the disc plate-to-pad friction surface using a brake cleaner.
2. Measure the points indicated in the illustration using a caliper (micrometer).
3. Subtract the minimum value from the maximum.
• If the result is not within specification,
machine the disc plate using a lathe.

Thickness variation limit

0.015 mm {0.0005 in}

Warning
• Do not exceed minimum disc plate
thickness.

ac9uuw00001431
04-11

Disc Plate Thickness Inspection

Caution
• Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine
the disc plate while installed on the vehicle.

1. Measure the thickness of the disc plate.

• If the thickness is not within the specification, replace the disc plate.

Minimum rear disc plate thickness

16 mm {0.63 in}

Minimum rear disc plate thickness after machining using a brake lathe on-vehicle
16.8 mm {0.66 in}

Disc Pad Thickness Inspection

1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Verify the remaining thickness of the pads.
• Replace the pads as a set: right and left
wheels, if either one is at or less than the
minimum thickness.

Minimum rear disc pad thickness

2.0 mm {0.08 in}

End Of Sie

ac9uuw00001432

04-11–19
1890-1U-06H(04-11).fm 20 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

REAR BRAKE (DISC) REMOVAL/INSTALLATION
id041100800500
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See 04-11-3 AIR BLEEDING.)
4. After installation, do the following.
(1) Depress the brake pedal a few times. Then verify that the brakes do not drag.
(2) Inspect the parking brake pedal stroke. (See 04-12-2 PARKING BRAKE INSPECTION.)

21.6—29.4 2 21.6—31.4 {2.21—3.20, 16.0—23.1}

{2.21—2.99,
16.0—21.6} 3 SST

GREASE
9 R B
78.4—101.9
7 R 11
{8.00—10.39, 1
57.9—75.1} R 5
4
2
21.6—31.4 8
{2.21—3.20,
16.0—23.1}

10 R A 6

14
GREASE

GREASE
A B C

9.8—14.7 N·m
{100—149 kgf·cm,
87—130 in·lbf}

GREASE
13 C
4
12 5
GREASE

B RUBBER GREASE
GREASE

C BRAKE GREASE
N·m {kgf·m, ft·lbf}
ac9uuw00002361

1 Brake hose 9 Slide pin

2 Bolt 10 Bush
3 Caliper 11 Dust boot
(See 04-11-22 Caliper Installation Note.) 12 Plug
4 Disc pad 13 Screw
5 Shim (See 04-11-21 Disc Plate, Screw Installation Note.)
6 Guide plate 14 Disc plate
7 Bolt (See 04-11-21 Disc Plate Removal Note.)
(See 04-11-21 Disc Plate, Screw Installation Note.)
8 Mounting support

04-11–20
1890-1U-06H(04-11).fm 21 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

Disc Plate Removal Note
1. If any disc plate is difficult to remove, perform the following steps to remove it.
(1) Insert a flathead screwdriver into the service
hole and turn the adjuster in the direction of
the arrow to compress the parking brake
shoe.
(2) Remove the disc plate.

04-11

LEFT SIDE RIGHT SIDE

ac9uuw00001434

Disc Plate, Screw Installation Note

1. Install the disc plate and the screws.
2. Perform the following steps to adjust the shoe clearance after installing the disc plate and the screws.
(1) Insert a flathead screwdriver into the service
hole and turn the adjuster in the direction of
the arrow to expand the parking brake shoe
until the disc plate cannot rotate.

LEFT SIDE RIGHT SIDE

ac9uuw00001435
(2) Return the adjuster 13—25 notches in the
direction of the arrow.

Note
• Shoe clearance can be adjusted to 0.15 mm
{0.006 in} by returning the adjuster 15
notches.

(3) Rotate the disc plate and make sure it does

not drag.
LEFT SIDE RIGHT SIDE
ac9uuw00001436

04-11–21
1890-1U-06H(04-11).fm 22 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

Caliper Installation Note
1. Push the piston fully inward using the SST.
2. Install the caliper.
End Of Sie
WM: DISC PAD (REAR)

49 0221 600C

ac9uuw00001437

DISC PAD (REAR) REPLACEMENT

id041100800300
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, depress the brake pedal a few times, rotate the wheel by hand, and verify that the brake does
not drag.
21.6—31.4
{2.21—3.20,
16.0—23.1}
2
1
GREASE

3 SST
5

GREASE
A 6
5
A

4
GREASE

BRAKE GREASE

N·m {kgf·m, ft·lbf}

ac9uuw00002362

1 Clip 4 Disc pad

2 Bolt 5 Shim
3 Caliper 6 Guide plate
(See 04-11-20 REAR BRAKE (DISC) REMOVAL/
INSTALLATION)

End Of Sie
WM: CALIPER (REAR)

04-11–22
1890-1U-06H(04-11).fm 23 ページ ２００６年１２月１９日　火曜日　午前１１時４１分

CONVENTIONAL BRAKE SYSTEM

CALIPER (REAR) DISASSEMBLY/ASSEMBLY
id041100800600
1. Disassemble in the order indicated in the table.
1 Bleeder cap
2 Bleeder screw R
3 Piston 5
(See 04-11-23 Piston Disassembly Note) R 3
4 Dust seal 4 1
5 Piston seal
2
6.9—9.8 N·m
6 Caliper {71—99 kgf·cm,
62—86 in·lbf}
2. Assemble in the reverse order of removal.
6

GREASE
BRAKE
FLUID

04-11

GREASE
GREASE
RUBBER GREASE

ac9uuw00001439

Piston Disassembly Note

Warning
• When compressed air is blown into the caliper body, injury to a finger or other part from pinching
could result from the piston springing up. When blowing in compressed air, do not place your
fingers between the piston and caliper body when performing the work.

Caution
• The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.

1. Place a piece of wood in the caliper, then blow

WOOD PLATE
compressed air through the hole to force the
piston out of the caliper.
End Of Sie

ac9uuw00001440

04-11–23
1890-1U-06H(04-12).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

04-12 PARKING BRAKE SYSTEM
PARKING BRAKE SYSTEM Adjusting Nut Installation Note . . . . . . . 04-12–7
LOCATION INDEX. . . . . . . . . . . . . . . . . 04-12–1 PARKING BRAKE
PARKING BRAKE INSPECTION . . . . . . 04-12–2 REMOVAL/INSTALLATION
PARKING BRAKE [AWD] . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-12–7
ADJUSTMENT . . . . . . . . . . . . . . . . . . . 04-12–2 Brake Caliper Component
PARKING BRAKE Removal Note . . . . . . . . . . . . . . . . . . . 04-12–9
REMOVAL/INSTALLATION Disc Plate Removal Note . . . . . . . . . . . 04-12–9
[2WD]. . . . . . . . . . . . . . . . . . . . . . . . . . . 04-12–2 Parking Brake Shoe
Brake Caliper Component Removal Note . . . . . . . . . . . . . . . . . . . 04-12–9
Removal Note . . . . . . . . . . . . . . . . . . 04-12–4 Operation lever, Pin, Adjuster
Disc Plate Removal Note . . . . . . . . . . . 04-12–4 Bolt and Nut, Tappet
Parking Brake Shoe Installation Note . . . . . . . . . . . . . . . . . 04-12–10
Removal Note . . . . . . . . . . . . . . . . . . 04-12–5 Parking Brake Shoe
Operation lever, Pin, Adjuster Installation Note . . . . . . . . . . . . . . . . . 04-12–10 04-12
Bolt and Nut, Tappet Disc Plate, Screw
Installation Note . . . . . . . . . . . . . . . . . 04-12–5 Installation Note . . . . . . . . . . . . . . . . . 04-12–10
Parking Brake Shoe Front Parking Brake Cable
Installation Note . . . . . . . . . . . . . . . . . 04-12–5 Installation Note . . . . . . . . . . . . . . . . . 04-12–11
Disc Plate, Screw Adjusting Nut Installation Note . . . . . . . 04-12–11
Installation Note . . . . . . . . . . . . . . . . . 04-12–6 PARKING BRAKE SWITCH I
Front Parking Brake Cable NSPECTION . . . . . . . . . . . . . . . . . . . . . . 04-12–12
Installation Note . . . . . . . . . . . . . . . . . 04-12–6

End of Toc
PARKING BRAKE SYSTEM LOCATION INDEX
WM: PARKING BRAKE SYSTEM

id041200800100

ac9uuw00001127

1 Parking brake (pedal type) 2 Parking brake switch

(See 04-12-2 PARKING BRAKE INSPECTION.) (See 04-12-12 PARKING BRAKE SWITCH
(See 04-12-2 PARKING BRAKE ADJUSTMENT.) INSPECTION.)
(See 04-12-2 PARKING BRAKE REMOVAL/
INSTALLATION [2WD].)
(See 04-12-7 PARKING BRAKE REMOVAL/
INSTALLATION [AWD].)

End Of Sie
WM: PARKING BRAKE

04-12–1
1890-1U-06H(04-12).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

PARKING BRAKE INSPECTION
id041200800300
1. Depress the parking brake pedal a few times.
2. Depress the brake pedal a few times.
3. Inspect the parking brake stroke by depressing the parking brake pedal with a force of 180 N {18.4 kgf, 40.5
lbf}.

Parking brake pedal stroke when depressed at 180 N {18.4 kgf, 40.5 lbf}
1—3 notches

End Of Sie
PARKING BRAKE ADJUSTMENT
id041200800400
1. Turn the adjusting nut at the front of the parking
cable.
2. After adjustment, inspect the following points:
(1) Turn the ignition switch on, depress the
parking brake pedal one notch, and verify that
the brake system warning light illuminates.
ADJUSTING NUT
(2) Verify that the rear brakes do not drag.
End Of Sie

acxuuw00001058

PARKING BRAKE REMOVAL/INSTALLATION [2WD]

id0412008002a1

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Perform the following procedure and remove the parking brake pedal.
(1) Remove the dashboard under cover (LH). (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
2. Perform the following procedure and remove the front parking brake cable.
(1) Remove the front seat (Driver side). (See 09-13-3 FRONT SEAT REMOVAL/INSTALLATION.)
(2) Remove the decoration panel. (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(3) Remove the front console box mat. (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/
INSTALLATION.)
(4) Remove the indicator panel. (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(5) Remove the front console box. (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(6) Remove the dashboard under cover (LH). (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
(7) Remove the side wall. (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(8) Remove the console panel. (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(9) Remove the console cover. (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(10)Remove the console. (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(11)Remove the dust cover.
(12)Remove the front side trim (LH). (See 09-17-23 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(13)Remove the front scuff plate (LH). (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(14)Remove the fuel-filler lid release lever cover.
(15)Turn the floor covering over until the front parking brake cable cover appears.
(16)Remove the rear heat duct (LH). (See 07-11-11 REAR HEAT DUCT COMPONENT REMOVAL/
INSTALLATION.)
(17)Remove the under guard (LH). (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID
VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.5].)

04-12–2
1890-1U-06H(04-12).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

3. Perform the following procedure and remove the rear parking brake cable.
(1) Remove the under guard (LH). (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID
VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.5].)
4. Perform the following procedure and remove the parking brake plate, back plate and wheel hub.
(1) Remove the rear ABS wheel-speed sensor from the rear wheel hub. (See 04-18-13 REAR ABS WHEEL-
SPEED SENSOR REMOVAL/INSTALLATION [2WD].)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Adjust the parking brake stroke. (See 04-12-2 PARKING BRAKE ADJUSTMENT.)

1 4 18.6—25.5
{1.90—2.60,
A 13.8—18.8}
3

C 8
18.6—25.5
04-12
{1.90—2.60, B 18.6—25.5
13.8—18.8}
{1.90—2.60,
13.8—18.8}
5 E

2 D D
A
C B
6
9

18.6—25.5
18.6—25.5 {1.90—2.60,
{1.90—2.60, 13.8—18.8}
13.8—18.8} 17—15.5
7
{12.0—15.8, 78.4—101.9
8 86.3—114} {8.0—10.3,
57.9—75.1}

22
23
24 10
20
E 21

3.6—5.1 N·m
15
{37—52 kgf·cm, 16
43—61 32—45 in·lbf}
{4.4—6.2, 13
32—44} 20
19
18 17
GREASE

11
14
8.5—9.5 N·m
{87—96 kgf·cm,
76—84in·lbf}

9.8—14.7 N·m
{100—149 kgf·cm, 12
87—130in·lbf}
N·m {kgf·m, ft·lbf}
ac9uuw00002364

1 Parking brake switch connector 9 Front Parking brake cable, equalizer

2 Adjusting nut (See 04-12-6 Front Parking Brake Cable Installation
(See 04-12-7 Adjusting Nut Installation Note.) Note.)
3 Parking brake switch 10 Brake caliper component
(See 04-12-4 Brake Caliper Component Removal
4 Dashboard under cover bracket Note)
5 Parking brake pedal 11 Plug
6 Spring 12 Screw
7 Clip (See 04-12-6 Disc Plate, Screw Installation Note)
8 Rear parking brake cable

04-12–3
1890-1U-06H(04-12).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

13 Disc plate 20 Adjuster bolt and nut, tappet
(See 04-12-4 Disc Plate Removal Note) (See 04-12-5 Operation lever, Pin, Adjuster Bolt and
(See 04-12-6 Disc Plate, Screw Installation Note) Nut, Tappet Installation Note)
14 Spring 21 Pin
15 Parking brake shoe (See 04-12-5 Operation lever, Pin, Adjuster Bolt and
(See 04-12-5 Parking Brake Shoe Removal Note) Nut, Tappet Installation Note.)
(See 04-12-5 Parking Brake Shoe Installation Note) 22 Operation lever
16 Rear wheel hub component (See 04-12-5 Operation lever, Pin, Adjuster Bolt and
Nut, Tappet Installation Note.)
17 Shoe stopper
23 Plate
18 Backing plate
24 Dust boot
19 Parking brake plate

Brake Caliper Component Removal Note

1. Remove the brake caliper assembly from the
trailing link and suspend it with a cable so it does
not interfere.

ampjjw00002740

Disc Plate Removal Note

1. If any disc plate is difficult to remove, perform the following steps to remove it.
(1) Insert a flathead screwdriver into the service
hole and turn the adjuster in the direction of
the arrow to compress the parking brake
shoe.
(2) Remove the disc plate.

LEFT SIDE RIGHT SIDE

ac9uuw00002285

04-12–4
1890-1U-06H(04-12).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

Parking Brake Shoe Removal Note
1. Pull the parking brake shoe downward and PARKING BRAKE SHOE
disengage it from the shoe stopper.
2. Press the adjuster bolt and tappet by hand, and SHOE STOPPER
slowly remove the parking brake shoe.

Note
• When removing the parking brake shoe,
firmly press the adjuster bolt and tappet by
hand and slowly remove the parking brake
shoe to prevent the adjuster bolt, tappet,
operation lever and other parts from flying
off.
am8rrw00001682

Operation lever, Pin, Adjuster Bolt and Nut, Tappet Installation Note 04-12
1. Install the operation lever, pin, adjuster bolt and
OPERATION LEVER
nut, and tappet so that the adjuster nut is facing
toward the vehicle front.
2. Completely tighten the adjuster bolt and nut. ADJUSTER BOLT
3. Move the operation lever by hand and verify that it
operates properly.
TAPPET
• If proper operation cannot be verified,
reinstall.
FRONT

ADJUSTER NUT PIN

acxuuw00001052

Parking Brake Shoe Installation Note

1. Measure the parking brake lining thickness with a
vernier caliper or measuring scale.
• If it is less than the minimum thickness, install
a new parking brake shoe.

Minimum parking brake shoe thickness

1.0 mm {0.04 in}

2. Apply grease to the contact surface of the parking

brake shoe and shoe stopper.

acxuuw00001053

3. After installing the opening of the parking brake PARKING BRAKE SHOE
shoe to the adjuster bolt and tappet, push the
brake shoe upward and attach it to the shoe SHOE STOPPER
stopper.

SHOE STOPPER

PARKING BRAKE SHOE

BACKING
PLATE
am8rrw00001683

04-12–5
1890-1U-06H(04-12).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

Disc Plate, Screw Installation Note
1. Measure the inner diameter of the disc plate with
a vernier caliper.
• If it exceeds the maximum diameter, install
the new disc plate.

Maximum rear disc plate inner diameter

191.0 mm {7.52 in}

2. Install the disc plate and screw.

acxuuw00001055
3. Perform the following steps to adjust the shoe clearance after installing the disc plate and the screws.
(1) Insert a flathead screwdriver into the service
hole and turn the adjuster in the direction of
the arrow to expand the parking brake shoe
until the disc plate cannot rotate.

LEFT SIDE RIGHT SIDE

ac9uuw00002286
(2) Return the adjuster 13—25 notches in the
direction of the arrow.

Note
• Shoe clearance can be adjusted to 0.15 mm
{0.006 in} by returning the adjuster 15
notches.

(3) Rotate the disc plate and make sure it does

not drag.
LEFT SIDE RIGHT SIDE
ac9uuw00002287
Front Parking Brake Cable Installation Note
1. Install the front parking brake cable and equalizer
so that the installation area of the equalizer spring
is on the underside of the vehicle as shown in the SPRING INSTALLATION
vehicle. PART

LOWER SIDE OF
VEHICLE

am8rrw00001684

04-12–6
1890-1U-06H(04-12).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

Adjusting Nut Installation Note
1. Verify that the front parking brake cable is
FRONT PARKING
installed below the cable deviation prevention tab BRAKE CABLE
of the brake cable. TAB
2. Install the adjusting nut.
End Of Sie

am8rrw00001685

PARKING BRAKE REMOVAL/INSTALLATION [AWD]

id0412008002a4
04-12
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Perform the following procedure and remove the parking brake pedal.
(1) Remove the dashboard under cover (LH). (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
2. Perform the following procedure and remove the front parking brake cable.
(1) Remove the front seat (Driver side). (See 09-13-3 FRONT SEAT REMOVAL/INSTALLATION.)
(2) Remove the decoration panel. (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(3) Remove the front console box mat. (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/
INSTALLATION.)
(4) Remove the indicator panel. (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(5) Remove the front console box. (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(6) Remove the dashboard under cover (LH). (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
(7) Remove the side wall. (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(8) Remove the console panel. (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(9) Remove the console cover. (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(10)Remove the console. (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(11)Remove the dust cover.
(12)Remove the front side trim (LH). (See 09-17-23 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(13)Remove the front scuff plate (LH). (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(14)Remove the fuel-filler lid release lever cover.
(15)Turn the floor covering over until the front parking brake cable cover appears.
(16)Remove the rear heat duct (LH). (See 07-11-11 REAR HEAT DUCT COMPONENT REMOVAL/
INSTALLATION.)
(17)Remove the under guard (LH). (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID
VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.5].)
3. Perform the following procedure and remove the rear parking brake cable.
(1) Remove the under guard. (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID
VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.5].)
4. Perform the following procedure and remove the parking brake plate, back plate and wheel hub.
(1) Remove the rear ABS wheel-speed sensor from the trailing link. (See 04-18-14 REAR ABS WHEEL-
SPEED SENSOR REMOVAL/INSTALLATION [AWD].)
(2) Remove the rear lateral link. (See 02-14-9 REAR LATERAL LINK REMOVAL/INSTALLATION.)
(3) Remove the rear coil spring. (See 02-14-5 REAR COIL SPRING REMOVAL/INSTALLATION.)
(4) Remove the trailing link component. (See 02-14-16 TRAILING LINK REMOVAL/INSTALLATION [AWD].)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Adjust the parking brake stroke. (See 04-12-2 PARKING BRAKE ADJUSTMENT.)
8. Inspect the rear wheel alignment. (See 02-11-5 REAR WHEEL ALIGNMENT [AWD].)

04-12–7
1890-1U-06H(04-12).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

1 4 18.6—25.5
{1.90—2.60,
A 13.8—18.8}
3

C 8
18.6—25.5
{1.90—2.60, B 18.6—25.5
13.8—18.8}
{1.90—2.60,
13.8—18.8}
5 E

2 D D
A
C B
6
9

18.6—25.5
18.6—25.5 {1.90—2.60,
{1.90—2.60, 13.8—18.8}
13.8—18.8} 17—15.5
7
{12.0—15.8, 78.4—101.9
8 86.3—114} {8.0—10.3,
57.9—75.1}

22
23
24 10
20
E 21

3.6—5.1 N·m
15
{37—52 kgf·cm, 16
43—61 32—45 in·lbf}
{4.4—6.2, 13
32—44} 20
19
18 17
GREASE

11
14
8.5—9.5 N·m
{87—96 kgf·cm,
76—84 in·lbf}

9.8—14.7 N·m
{100—149 kgf·cm, 12
87—130 in·lbf}
N·m {kgf·m, ft·lbf}
ac9uuw00002366
.

1 Parking brake switch connector 15 Parking brake shoe

2 Adjusting nut (See 04-12-9 Parking Brake Shoe Removal Note)
(See 04-12-10 Parking Brake Shoe Installation
3 Parking brake switch
Note)
4 Dashboard under cover bracket
16 Rear wheel hub component
5 Parking brake pedal
17 Shoe stopper
6 Spring
18 Backing plate
7 Clip
19 Parking brake plate
8 Rear parking brake cable
Adjuster bolt and nut, tappet
9 Front Parking brake cable, equalizer 20 (See 04-12-10 Operation lever, Pin, Adjuster Bolt
10 Brake caliper component and Nut, Tappet Installation Note)
(See 04-12-9 Brake Caliper Component Removal Pin
Note) 21 (See 04-12-10 Operation lever, Pin, Adjuster Bolt
11 Plug and Nut, Tappet Installation Note)
12 Screw Operation lever
(See 04-12-10 Disc Plate, Screw Installation Note) 22 (See 04-12-10 Operation lever, Pin, Adjuster Bolt
13 Disc plate and Nut, Tappet Installation Note)
(See 04-12-9 Disc Plate Removal Note) 23 Plate
(See 04-12-10 Disc Plate, Screw Installation Note) 24 Dust boot
14 Spring

04-12–8
1890-1U-06H(04-12).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

Brake Caliper Component Removal Note
1. Remove the brake caliper assembly from the
trailing link and suspend it with a cable so it does
not interfere.

ampjjw00002740

Disc Plate Removal Note 04-12

1. If any disc plate is difficult to remove, perform the following steps to remove it.
(1) Insert a flathead screwdriver into the service
hole and turn the adjuster in the direction of
the arrow to compress the parking brake
shoe.
(2) Remove the disc plate.

LEFT SIDE RIGHT SIDE

ac9uuw00002288

Parking Brake Shoe Removal Note

1. Pull the parking brake shoe downward and PARKING BRAKE SHOE
disengage it from the shoe stopper.
2. Press the adjuster bolt and tappet by hand, and SHOE STOPPER
slowly remove the parking brake shoe.

Note
• When removing the parking brake shoe,
firmly press the adjuster bolt and tappet by
hand and slowly remove the parking brake
shoe to prevent the adjuster bolt, tappet,
operation lever and other parts from flying
off.
am8rrw00001682

04-12–9
1890-1U-06H(04-12).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時４３分

PARKING BRAKE SYSTEM

Operation lever, Pin, Adjuster Bolt and Nut, Tappet Installation Note
1. Install the operation lever, pin, adjuster bolt and
OPERATION LEVER
nut, and tappet so that the adjuster nut is facing
toward the vehicle front.
2. Completely tighten the adjuster bolt and nut. ADJUSTER BOLT
3. Move the operation lever by hand and verify that it
operates properly.
TAPPET
• If proper operation cannot be verified,
reinstall.
FRONT

ADJUSTER NUT PIN

acxuuw00001052

Parking Brake Shoe Installation Note

1. Measure the parking brake lining thickness with a
vernier caliper or measuring scale.
• If it is less than the minimum thickness, install
a new parking brake shoe.

Minimum parking brake shoe thickness

1.0 mm {0.04 in}

2. Apply grease to the contact surface of the parking

brake shoe and shoe stopper.

acxuuw00001053

3. After installing the opening of the parking brake PARKING BRAKE SHOE
shoe to the adjuster bolt and tappet, push the
brake shoe upward and attach it to the shoe SHOE STOPPER
stopper.

SHOE STOPPER

PARKING BRAKE SHOE

BACKING
PLATE
am8rrw00001683

Disc Plate, Screw Installation Note

1. Measure the inner diameter of the disc plate with
a vernier caliper.
• If it exceeds the maximum diameter, install
the new disc plate.

Maximum rear disc plate inner diameter

191.0 mm {7.52 in}

2. Install the disc plate and screw.

acxuuw00001055

04-12–10
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PARKING BRAKE SYSTEM

3. Perform the following steps to adjust the shoe clearance after installing the disc plate and the screws.
(1) Insert a flathead screwdriver into the service
hole and turn the adjuster in the direction of
the arrow to expand the parking brake shoe
until the disc plate cannot rotate.

04-12

LEFT SIDE RIGHT SIDE

ac9uuw00002289
(2) Return the adjuster 13—25 notches in the
direction of the arrow.

Note
• Shoe clearance can be adjusted to 0.15 mm
{0.006 in} by returning the adjuster 15
notches.

(3) Rotate the disc plate and make sure it does

not drag.
LEFT SIDE RIGHT SIDE
ac9uuw00002290
Front Parking Brake Cable Installation Note
1. Install the front parking brake cable and equalizer
so that the installation area of the equalizer spring
is on the underside of the vehicle as shown in the SPRING INSTALLATION
vehicle. PART

LOWER SIDE OF
VEHICLE

am8rrw00001684
Adjusting Nut Installation Note
1. Verify that the front parking brake cable is
FRONT PARKING
installed below the cable deviation prevention tab BRAKE CABLE
of the brake cable. TAB
2. Install the adjusting nut.
End Of Sie
WM: PARKING BRAKE SWITCH

am8rrw00001685

04-12–11
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PARKING BRAKE SYSTEM

PARKING BRAKE SWITCH INSPECTION
id041200800700
1. Disconnect the parking brake switch connector.
2. Verify that the continuity is as indicated in the
table.
• If not as indicated in the table, replace the
parking brake switch. (See 04-12-2 PARKING
BRAKE REMOVAL/INSTALLATION [2WD].) A
(See 04-12-7 PARKING BRAKE REMOVAL/
INSTALLATION [AWD].)
: Continuity

Terminal
Condition Body
A
ground ampjjw00002631

Parking brake pedal depressed

Parking brake pedal released

acxuuw00001059

End Of Sie

04-12–12
1890-1U-06H(04-18).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

04-18 DYNAMIC STABILITY CONTROL/ROLL STABILITY
CONTROL
DSC/RSC LOCATION INDEX . . . . . . . . . 04-18–2 REAR ABS WHEEL-SPEED SENSOR
DSC/RSC SYSTEM REMOVAL/INSTALLATION
WIRING DIAGRAM . . . . . . . . . . . . . . . . 04-18–3 [2WD] . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-18–13
DSC/RSC SYSTEM INSPECTION . . . . . 04-18–4 REAR ABS WHEEL-SPEED SENSOR
Preparation . . . . . . . . . . . . . . . . . . . . . 04-18–4 REMOVAL/INSTALLATION
ABS Control Inspection . . . . . . . . . . . . 04-18–4 [AWD] . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-18–14
DSC Control Inspection . . . . . . . . . . . . 04-18–5 REAR ABS WHEEL-SPEED SENSOR
DSC/RSC HU/CM INSPECTION [2WD] . . . . . . . . . . . . . . . . 04-18–14
REMOVAL/INSTALLATION. . . . . . . . . . 04-18–6 Installation Visual Inspection. . . . . . . . . 04-18–14
DSC/RSC HU/CM Connector Clearance Inspection . . . . . . . . . . . . . . 04-18–14
Removal Note . . . . . . . . . . . . . . . . . . 04-18–7 Sensor Output Value Inspection . . . . . . 04-18–15
Brake Pipe Removal Note . . . . . . . . . . 04-18–8 REAR ABS WHEEL-SPEED SENSOR 04-18
DSC/RSC HU/CM INSPECTION [AWD] . . . . . . . . . . . . . . . 04-18–15
Component Installation Note . . . . . . . 04-18–8 Installation Visual Inspection. . . . . . . . . 04-18–15
Brake Pipe Installation Note. . . . . . . . . 04-18–8 Clearance Inspection . . . . . . . . . . . . . . 04-18–15
DSC/RSC HU/CM Connector Sensor Output Value Inspection . . . . . . 04-18–15
Installation Note . . . . . . . . . . . . . . . . . 04-18–8 COMBINED SENSOR
DSC/RSC HU AIR BLEEDING . . . . . . . . 04-18–9 REMOVAL/INSTALLATION . . . . . . . . . . 04-18–16
DSC/RSC SENSOR INITIALIZATION COMBINED SENSOR
PROCEDURE . . . . . . . . . . . . . . . . . . . . 04-18–9 INSPECTION . . . . . . . . . . . . . . . . . . . . . 04-18–17
DSC/RSC HU/CM INSPECTION . . . . . . . 04-18–10 BRAKE FLUID PRESSURE
Standard (Reference Value). . . . . . . . . 04-18–10 SENSOR INSPECTION . . . . . . . . . . . . . 04-18–19
FRONT ABS WHEEL-SPEED SENSOR TCS OFF SWITCH
REMOVAL/INSTALLATION. . . . . . . . . . 04-18–11 REMOVAL/INSTALLATION . . . . . . . . . . 04-18–20
FRONT ABS WHEEL-SPEED SENSOR TCS OFF Switch
INSPECTION . . . . . . . . . . . . . . . . . . . . . 04-18–12 Removal Note . . . . . . . . . . . . . . . . . . . 04-18–20
Installation Visual Inspection . . . . . . . . 04-18–12 TCS OFF SWITCH
Clearance Inspection . . . . . . . . . . . . . 04-18–12 INSPECTION . . . . . . . . . . . . . . . . . . . . . 04-18–20
Sensor Output Value Inspection . . . . . 04-18–12

End of Toc
WM: ROLL STABILITY CONTROL

04-18–1
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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

DSC/RSC LOCATION INDEX
id041800816000

2WD 3

4
6

5 1

AWD

ac9uuw00001387

1 DSC/RSC HU/CM 3 Rear ABS wheel-speed sensor

(See 04-18-3 DSC/RSC SYSTEM WIRING (See 04-18-13 REAR ABS WHEEL-SPEED
DIAGRAM.) SENSOR REMOVAL/INSTALLATION [2WD].)
(See 04-18-4 DSC/RSC SYSTEM INSPECTION.) (See 04-18-14 REAR ABS WHEEL-SPEED
(See 04-18-6 DSC/RSC HU/CM REMOVAL/ SENSOR REMOVAL/INSTALLATION [AWD].)
INSTALLATION.) (See 04-18-14 REAR ABS WHEEL-SPEED
(See 04-18-9 DSC/RSC HU AIR BLEEDING.) SENSOR INSPECTION [2WD].)
(See 04-18-9 DSC/RSC SENSOR INITIALIZATION (See 04-18-15 REAR ABS WHEEL-SPEED
PROCEDURE.) SENSOR INSPECTION [AWD].)
(See 04-18-10 DSC/RSC HU/CM INSPECTION.) 4 Combined sensor
2 Front ABS wheel-speed sensor (See 04-18-16 COMBINED SENSOR REMOVAL/
(See 04-18-11 FRONT ABS WHEEL-SPEED INSTALLATION.)
SENSOR REMOVAL/INSTALLATION.) (See 04-18-17 COMBINED SENSOR
(See 04-18-12 FRONT ABS WHEEL-SPEED INSPECTION.)
SENSOR INSPECTION.) 5 Brake fluid pressure sensor (built-into RSC HU/CM)
(See 04-18-19 BRAKE FLUID PRESSURE
SENSOR INSPECTION.)
6 TCS OFF switch
(See 04-18-20 TCS OFF SWITCH REMOVAL/
INSTALLATION.)
(See 04-18-20 TCS OFF SWITCH INSPECTION.)

04-18–2
1890-1U-06H(04-18).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

End Of Sie

DSC/RSC SYSTEM WIRING DIAGRAM

id041800816100

ABS (SOL) 30A TCS OFF LIGHT DSC INDICATOR

AL
LIGHT
ABS WARNING BRAKE SYSTEM
LIGHT WARNING LIGHT

IG 1
ABS 50A
AK

B
SAS 7.5A
X
IG SW 04-18

BATTERY

INSTRUMENT CLUSTER

PCM
E CAN2_L
COMBINED C M
SENSOR D P DSC/RSC HU/CM +B
CAN2_H
B
HS_CAN_H
Y
V STEERING
HS_CAN_L
BCM ANGLE
SENSOR

AE
RF
AB

AG DLC-2
LF
AD
ABS WHEEL-
SPEED SENSOR
RR G
J

TCS OFF SWITCH

LR F
I U

ac9uuw00002273

End Of Sie

04-18–3
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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

DSC/RSC SYSTEM INSPECTION
id041800816200
Preparation
1. Verify that battery is fully charged.
2. Turn the ignition switch to the ON position, and verify that the ABS warning light goes out after approx. 3 s.
3. Turn the ignition switch off.
4. Jack up the vehicle and support it evenly on safety stands.
5. Shift to the N position.
6. Verify that all four wheels rotate.
7. Rotate the inspected wheels by hand, and verify there is no brake drag.
• If there is any brake drag, perform regular brake inspection.
• If there is no brake drag, perform DSC/RSC HU/CM operation inspection.
ABS Control Inspection
1. Perform “Preparation”.
2. Connect the M-MDS to the DLC-2.
3. Set up an active command mode inspection
according to the combination of commands
below.

DLC-2

ac9uuw00000862
Brake pressure retention
Inspected wheels
Command name
LF RF LR RR
V_TRC_L
V_TRC_R
OFF
V_STB_L
V_STB_R
V_LF_INL ON
OFF
V_LF_OTL
OFF
V_LR_INL ON
OFF
V_LR_OTL
V_RF_INL OFF ON
V_RF_OTL OFF
V_RR_INL OFF ON
V_RR_OTL OFF
PMP_MOTOR OFF

Brake pressure reduction

Inspected wheels
Command name
LF RF LR RR
V_TRC_L
V_TRC_R
OFF
V_STB_L
V_STB_R
V_LF_INL
ON OFF
V_LF_OTL
OFF
V_LR_INL
ON OFF
V_LR_OTL
V_RF_INL
OFF ON
V_RF_OTL
OFF
V_RR_INL
OFF ON
V_RR_OTL
PMP_MOTOR ON

04-18–4
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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

Caution
• To protect the DSC/RSC HU/CM, the solenoid valve and the pump motor used during active
command mode stay on for only 10 s or less each time they are switched on.

Note
• When working with two people, one should press on the brake pedal, and the other should attempt to
rotate the wheel being inspected.

4. Send the command while depressing on the brake pedal and attempting to rotate the wheel being inspected.
5. While brake pressure is maintained and a DSC/RSC HU/CM operation click sound is heard, confirm that the
wheel does not rotate. While brake pressure is being reduced and an DSC/RSC HU/CM operation click sound
is heard, confirm that the wheel rotates.
• Performing the inspection above determines the following:
— The DSC/RSC HU/CM brake lines are normal.
— The DSC/RSC HU/CM hydraulic system is not significantly abnormal (including DSC/RSC HU/CM).
— The DSC/RSC HU/CM internal electrical parts (solenoid, motor and other parts) are normal. 04-18
— The DSC/RSC unit and DSC/RSC HU/CM output system wiring harnesses (solenoid valve, relay
system) are normal.
• However, the following items cannot be verified.
— Malfunction with intermittent occurrence of the above items
— Malfunction of DSC/RSC HU/CM input system wiring harnesses and parts
— Extremely small leaks in the DSC/RSC HU/CM internal hydraulic system

DSC Control Inspection

1. Perform “Preparation”.
2. Connect the M-MDS to the DLC-2.

DLC-2

ac9uuw00000862

3. Set up an active command mode inspection according to the combination of commands below.

Caution
• To protect the DSC/RSC HU/CM, the solenoid valve and the pump motor used during active
command mode stay on for only 10 s or less each time they are switched on.

Inspected wheels
Command name Understeer control inhibited Oversteer control inhibited
LF RF LR RR
V_TRC_L ON OFF ON
V_TRC_R OFF ON OFF
V_STB_L
OFF
V_STB_R
V_LF_INL ON
OFF
V_LF_OTL
OFF
V_LR_INL ON
OFF
V_LR_OTL
V_RF_INL ON OFF
V_RF_OTL OFF
V_RR_INL ON OFF
V_RR_OTL OFF
PMP_MOTOR ON

04-18–5
1890-1U-06H(04-18).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

4. Send the command while rotating the wheel being inspected by hand in a forward direction.
5. Confirm that the wheel does not rotate easily while a DSC/RSC HU/CM operation click sound is heard.
• Performing the inspection above determines the following:
— The DSC/RSC HU/CM brake lines are normal.
— The DSC/RSC HU/CM hydraulic system is not significantly abnormal (including DSC/RSC HU/CM).
— The DSC/RSC HU/CM internal electrical parts (solenoid, motor and other parts) are normal.
— The DSC/RSC unit and DSC/RSC HU/CM output system wiring harnesses (solenoid valve, relay
system) are normal.
• However, the following items cannot be verified.
— Malfunction with intermittent occurrence of the above items
— Malfunction of DSC/RSC HU/CM input system wiring harnesses and parts
— Extremely small leaks in the DSC/RSC HU/CM internal hydraulic system
End Of Sie
DSC/RSC HU/CM REMOVAL/INSTALLATION
id041800816300

Warning
• If the DSC/RSC sensor initialization procedure is not completed, it could result in an unexpected
accident due to the DSC/RSC being inoperative. Therefore, after the DSC/RSC HU/CM is replaced,
always perform the DSC/RSC sensor initialization procedure to ensure proper DSC/RSC operation.
(See 04-18-9 DSC/RSC SENSOR INITIALIZATION PROCEDURE.)

Caution
• The internal parts of the DSC/RSC HU/CM could be damaged if dropped. Be careful not to drop the
DSC/RSC HU/CM. Replace the DSC/RSC HU/CM if it is subjected to an impact.

1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Remove the battery tray bracket as shown in the
figure. 18—26 N·m
3. Remove the windshield wiper arm and blade. {1.9—2.6 kgf·m,
14—19 ft·lbf}
(See 09-19-3 WINDSHIELD WIPER ARM AND
BLADE REMOVAL/INSTALLATION.)
4. Remove the cowl grille. (See 09-16-13 COWL
GRILLE REMOVAL/INSTALLATION.)
5. Remove the wiper motor. (See 09-19-4
WINDSHIELD WIPER MOTOR REMOVAL/
INSTALLATION.)
BATTERY TRY BRACKET
6. Remove the cowl panel. (See 09-10-14 COWL
PANEL REMOVAL/INSTALLATION.)
ac9uuw00001267

7. Remove the nuts as shown in the figure, and

move the front heater pipe.
8. Remove in the order indicated in the table.
9. Install in the reverse order of removal.
10. After installation, add brake fluid, bleed the air,
and inspect for fluid leakage. (See 04-18-9 DSC/
RSC HU AIR BLEEDING.) (See 04-11-3 AIR
BLEEDING.)
11. After installation, perform the DSC/RSC sensor 8—12 N·m
initialization procedure. (See 04-18-9 DSC/RSC {82—122 kgf·cm,
71—106 in·lbf}
SENSOR INITIALIZATION PROCEDURE.)
FRONT HEATER PIPE
ac9uuw00001268

04-18–6
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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

7
2
B

B 18.6—25.5 N·m
{1.90—2.60 kgf·m,
12.8—21.6 13.8—18.8 ft·lbf}
{131—220, 6
114—191}
3 20—30 N·m
4
{2.1—3.0 kgf·m, C
15—22 ft·lbf}
C 04-18
7.8—10.8
1 A D 5 {80—110,
70—95}
A
E
D
7.8—10.8
{80—110,
70—95}
4 E
18.6—25.5 N·m
{1.90—2.60 kgf·m,
13.8—18.8 ft·lbf}
N·m {kgf·cm, in·lbf}
ac9uuw00001324

1 DSC/RSC HU/CM connector Brake pipe

(See 04-18-7 DSC/RSC HU/CM Connector 3 (See 04-18-8 Brake Pipe Removal Note.)
Removal Note.) (See 04-18-8 Brake Pipe Installation Note.)
(See 04-18-8 DSC/RSC HU/CM Connector 4 Bolt
Installation Note.)
DSC/RSC HU/CM component
Brake pipe (DSC/RSC HU/CM—master cylinder) 5 (See 04-18-8 DSC/RSC HU/CM Component
2 (See 04-18-8 Brake Pipe Removal Note.) Installation Note.)
(See 04-18-8 Brake Pipe Installation Note.)
6 DSC/RSC HU/CM bracket
7 DSC/RSC HU/CM

DSC/RSC HU/CM Connector Removal Note

1. Remove the DSC/RSC HU/CM connector using
the following procedure:
(1) Press down the lock lever while pressing the
upper tab to release the lock.
(2) Press down the lock lever and lock it using the
lower tab.
(3) Remove the DSC/RSC HU/CM connector by
pulling it in the direction of the arrow. 1
2
3

ac9uuw00001269

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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

Brake Pipe Removal Note
1. Place an alignment mark on the brake pipe and
DSC/RSC HU/CM.
2. Apply protective tape to the DSC/RSC HU/CM
connector to prevent brake fluid from entering. MARK
3. Remove the brake pipe.

MARK

ac9uuw00001325

DSC/RSC HU/CM Component Installation Note

1. Insert the DSC/RSC HU/CM bracket tab to the
vehicle frame hole as shown in the figure.
2. Install the DSC/RSC HU/CM component.

DSC/RSC HU/CM BRACKET

ac9uuw00002274

Brake Pipe Installation Note

1. Align the marks made before removal and install MASTER CYLINDER
the brake pipe to the DSC/RSC HU/CM and brake (PRIMARY SIDE) RF
pipe joint referring to the figure.
2. Tighten the brake pipe to the specified torque
using the SST (49 0259 770B) and the LR
commercially available flare nut wrench.
RR

LF
MASTER CYLINDER
(SECONDARY SIDE)
ac9uuw00001332

DSC/RSC HU/CM Connector Installation Note

1. Install the DSC/RSC HU/CM connector using the
following procedure:
(1) After verifying that the lock lever is locked by
the lower tab, connect the DSC/RSC HU/CM
connector to the DSC/RSC HU/CM.
(2) Pull up the lock lever by pressing the lower
tab, and release the lock. 3
(3) Pull up the lock lever and lock it using the
upper tab. 1
2. Verify that the DSC/RSC HU/CM connector is
installed securely. 2
End Of Sie ac9uuw00001270

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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

DSC/RSC HU AIR BLEEDING
id041800816500
1. Turn the ignition switch off.
2. Connect the M-MDS to the DLC-2 connector.
3. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (notebook PC)
1. Select the “Toolbox” tab.
2. Select “Chassis”.
3. Select “Braking”.
• When using the PDS (pocket PC)
1. Select “All Tests and Calibrations”. DLC-2
4. Then, select the “ABS Service Bleed” from the
screen menu.
5. Perform the air bleeding according to the
ac9uuw00000862
directions on the screen. 04-18
End Of Sie
DSC/RSC SENSOR INITIALIZATION PROCEDURE
id041800816400

Warning
• Unless the initialization procedure of the combined sensor is completed, the DSC/RSC will not
operate, causing an unexpected accident. Therefore, always perform the initialization procedure to
ensure DSC/RSC operation if the combined sensor and DSC/RSC HU/CM have been removed or
replaced.

1. Inspect the wheel alignment and inflation pressure.

• If there is any malfunction, adjust the applicable part.
2. Park the vehicle on level ground.
3. Turn the ignition switch off.
4. Connect the M-MDS to the DLC-2 connector.
5. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Chassis”.
3. Select “ABS/DSC”.
4. Select “Sensor Initialization”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Test”.
2. Select “ABS”.
3. Select “Datalogger”.
ac9uuw00000862
4. Select “SSR_INTL”.
6. Perform the initialization according to the
directions on the screen.
End Of Sie

04-18–9
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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

DSC/RSC HU/CM INSPECTION
id041800818600
1. Disconnect the DSC/RSC HU/CM connector. (See 04-18-6 DSC/RSC HU/CM REMOVAL/INSTALLATION.)
2. Connect the negative battery cable. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
3. Attach the tester lead to the DSC/RSC HU/CM harness side connector, then inspect voltage, continuity or
resistance according to the standard (reference value) on the table.

Standard (Reference Value)

DSC/RSC HU/CM WIRING HARNESS-SIDE CONNECTOR

AK AH AE AB Y V S P M J G D B
AI AF AC Z W T Q N K H E

AL AJ AG AD AA X U R O L I F C A

ac9uuw00002275

Measured Measured terminal

Terminal Signal name Connected to Standard Inspection item(s)
item (measured condition)
Ground
Continuity • Wiring harness (A—
A (DSC/RSC Ground point Continuity A—ground point
detected ground point)
system)
Ground Continuity • Wiring harness (B—
B Ground point Continuity B—ground point
(ABS motor) detected ground point)
C — — — — — —
D — — — — — —
E — — — — — —
LR wheel- • Wiring harness (F—LR
F—LR ABS wheel-
speed sensor LR ABS wheel- Continuity ABS wheel-speed
F Continuity speed sensor
(power speed sensor detected sensor connector
connector terminal B
supply) terminal B)
RR wheel- • Wiring harness (G—RR
G—RR ABS wheel-
speed sensor RR ABS wheel- Continuity ABS wheel-speed
G Continuity speed sensor
(power speed sensor detected sensor connector
connector terminal B
supply) terminal B)
H — — — — — —
• Wiring harness (I—LR
LR wheel- I—LR ABS wheel-
LR ABS wheel- Continuity ABS wheel-speed
I speed sensor Continuity speed sensor
speed sensor detected sensor connector
(signal) connector terminal A
terminal A)
• Wiring harness (J—RR
RR wheel- J—RR ABS wheel-
RR ABS wheel- Continuity ABS wheel-speed
J speed sensor Continuity speed sensor
speed sensor detected sensor connector
(signal) connector terminal A
terminal A)
K — — — — — —
L — — — — — —
M CAN2_L — Inspect under DTC inspection —
N — — — — — —
O — — — — — —
P CAN2_H — Inspect under DTC inspection —
Q — — — — — —
R — — — — — —
S — — — — — —
T — — — — — —
• Wiring harness (U—
TCS OFF U—TCS OFF switch Continuity
U TCS OFF switch Continuity TCS OFF switch
switch connector terminal A detected
connector terminal A)
V HS_CAN_L — Inspect under DTC inspection —
W — — — — — —

04-18–10
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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

Measured Measured terminal
Terminal Signal name Connected to Standard Inspection item(s)
item (measured condition)
• Wiring harness (X—
Power supply Ignition switch at ON B+
X Ignition switch Voltage ignition switch)
(system)
Ignition switch is off. 1 V or less —
Y HS_CAN_H — Inspect under DTC inspection —
Z — — — — — —
AA — — — — — —
• Wiring harness (AB—
RF wheel- AB—RF ABS wheel-
RF ABS wheel- Continuity RF ABS wheel-speed
AB speed sensor Continuity speed sensor
speed sensor detected sensor connector
(signal) connector terminal B
terminal B)
AC — — — — — —
• Wiring harness (AD—LF
LF wheel- AD—LF ABS wheel-
LF ABS wheel- Continuity ABS wheel-speed
AD speed sensor Continuity speed sensor 04-18
speed sensor detected sensor connector
(signal) connector terminal B
terminal B)
RF wheel- • Wiring harness (AE—
AE—RF ABS wheel-
speed sensor RF ABS wheel- Continuity RF ABS wheel-speed
AE Continuity speed sensor
(power speed sensor detected sensor connector
connector terminal A
supply) terminal A)
AF — — — — — —
LF wheel- • Wiring harness (AG—LF
AG—LF ABS wheel-
speed sensor LF ABS wheel- Continuity ABS wheel-speed
AG Continuity speed sensor
(power speed sensor detected sensor connector
connector terminal A
supply) terminal A)
AH — — — — — —
AI — — — — — —
AJ — — — — — —
Power supply
• Wiring harness (AK—
AK (ABS motor Battery Voltage Under any condition B+
battery)
operation)
Power supply
• Wiring harness (AL—
AL (solenoid Battery Voltage Under any condition B+
battery)
operation)

End Of Sie
FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION
WM: FRONT ABS WHEEL-SPEED SENSOR

id041800816700
1. When removing the right front ABS wheel-speed sensor, perform the following procedure.
(1) Remove the coolant reserve tank installation bolts and move the coolant reserve tank. (See 01-12-7
COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZI-3.5].)
(2) Remove the power steering reserve tank installation bolt and nut, and move the power steering reserve
tank. (See 06-14-20 POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)
2. When removing the left front ABS wheel-speed sensor, perform the following procedure:
(1) Remove the air cleaner case. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
3. Remove in the order indicated in the table.
1 Front ABS wheel-speed sensor connector
2 Bolt
3 Front ABS wheel-speed sensor 1

4. Install in the reverse order of removal.

End Of Sie 3

2
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
acxuuw00001205

04-18–11
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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

FRONT ABS WHEEL-SPEED SENSOR INSPECTION
id041800816800
Installation Visual Inspection
1. Inspect the following items:
• If there is any malfunction, replace the applicable part.
(1) Excessive play of the ABS wheel-speed sensor
(2) Deformation of the ABS wheel-speed sensor
(3) Deformation or damage of the ABS sensor rotor

Clearance Inspection
1. Verify the clearance between the ABS sensor FRONT ABS WHEEL-
rotor and the ABS wheel-speed sensor. SPEED SENSOR
• If there is any malfunction, check for improper
installation, and replace if necessary.

Clearance
• 0.7—1.5 mm {0.028—0.059 in} CLEARANCE

FRONT ABS
SENSOR ROTOR
acxuuw00001206

Sensor Output Value Inspection

1. Turn the ignition switch off.
2. Connect the M-MDS to the DLC-2 connector.
3. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Module”.
4. Select “ABS”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “ABS”.
3. Select “DataLogger”.
ac9uuw00000862
4. Select the following PIDs using the M-MDS:
• WSPD_LF
(LF ABS wheel-speed sensor)
• WSPD_RF
(RF ABS wheel-speed sensor)
5. Start the engine and drive the vehicle.
6. Verify that the display of the M-MDS shows the same value as the speedometer.
• If there is any malfunction, replace the front ABS wheel-speed sensor.
End Of Sie
WM: REAR ABS WHEEL-SPEED SENSOR

04-18–12
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DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [2WD]
id0418008169a1
1. Remove the trunk box. (See 09-17-29 TRUNK BOX REMOVAL/INSTALLATION.)
2. Remove the seat side box. (See 09-17-29 SEAT SIDE BOX REMOVAL/INSTALLATION.)
3. Remove the third-row seat. (See 09-13-22 THIRD-ROW SEAT REMOVAL/INSTALLATION.)
4. Remove the rear scuff plate inner. (See 09-17-24 REAR SCUFF PLATE REMOVAL/INSTALLATION.)
5. Remove the third-row seat belt lower anchor installation bolt. (See 08-11-5 THIRD-ROW SEAT BELT
REMOVAL/INSTALLATION.)
6. Remove the trunk side trim. (See 09-17-27 TRUNK SIDE TRIM REMOVAL/INSTALLATION.)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
1

04-18

2
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}

ac9uuw00001049

1 Rear ABS wheel-speed sensor connector 3 Rear ABS wheel-speed sensor

2 Bolt

End Of Sie

04-18–13
1890-1U-06H(04-18).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [AWD]
id0418008169b1
1. Remove the trunk box. (See 09-17-29 TRUNK BOX REMOVAL/INSTALLATION.)
2. Remove the seat side box. (See 09-17-29 SEAT SIDE BOX REMOVAL/INSTALLATION.)
3. Remove the third-row seat. (See 09-13-22 THIRD-ROW SEAT REMOVAL/INSTALLATION.)
4. Remove the rear scuff plate inner. (See 09-17-24 REAR SCUFF PLATE REMOVAL/INSTALLATION.)
5. Remove the third-row seat belt lower anchor installation bolt. (See 08-11-5 THIRD-ROW SEAT BELT
REMOVAL/INSTALLATION.)
6. Remove the trunk side trim. (See 09-17-27 TRUNK SIDE TRIM REMOVAL/INSTALLATION.)
7. Remove in the order indicated in the table.
1
1 Rear ABS wheel-speed sensor connector
2 Bolt
3 Rear ABS wheel-speed sensor

8. Install in the reverse order of removal. 7.8—10.8 N·m

{80—110 kgf·cm,
End Of Sie 70—95 in·lbf}

2 3

ac9uuw00001063

REAR ABS WHEEL-SPEED SENSOR INSPECTION [2WD]

id0418008170a1
Installation Visual Inspection
1. Inspect the following items:
• If there is any malfunction, replace the applicable part.
(1) Excessive play of the ABS wheel-speed sensor
(2) Deformation of the ABS wheel-speed sensor

Clearance Inspection
1. Remove the rear ABS wheel-speed sensor.
2. Measure the distance between the rear ABS
A
wheel-speed sensor installation surface and the CLEARANCE
ABS sensor rotor. This is dimension A. REAR ABS WHEEL-
3. Calculate the clearance between the front ABS SPEED SENSOR
wheel-speed sensor and the ABS sensor rotor
using the following formula:
REAR ABS
Clearance (mm {in}) = A-15.0 {0.60 in} SENSOR ROTOR
15.0 mm {0.60 in}
4. Verify that the clearance between the ABS sensor
rotor and the rear ABS wheel-speed sensor is as
indicated below.
• If there is any malfunction, replace it.
acxuuw00001203
Clearance
• 0.3—1.1 mm {0.012—0.043 in}

04-18–14
1890-1U-06H(04-18).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

Sensor Output Value Inspection
1. Turn the ignition switch off.
2. Connect the M-MDS to the DLC-2 connector.
3. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Module”.
4. Select “ABS”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “ABS”.
3. Select “DataLogger”.
4. Select the following PIDs using the M-MDS: ac9uuw00000862
• WSPD_LR
(LR ABS wheel-speed sensor) 04-18
• WSPD_RR
(RR ABS wheel-speed sensor)
5. Start the engine and drive the vehicle.
6. Verify that the display of the M-MDS shows the same value as the speedometer.
• If there is any malfunction, replace the rear ABS wheel-speed sensor.
End Of Sie
REAR ABS WHEEL-SPEED SENSOR INSPECTION [AWD]
id0418008170b1

Installation Visual Inspection

1. Inspect the following items:
• If there is any malfunction, replace the applicable part.
(1) Excessive play of the ABS wheel-speed sensor
(2) Deformation of the ABS wheel-speed sensor
(3) Deformation or damage of the ABS sensor rotor
Clearance Inspection
1. Verify the clearance between the ABS sensor rotor and the ABS wheel-speed sensor.
• If there is any malfunction, check for improper installation, and replace if necessary.

Clearance
• 0.95—1.75 mm {0.038—0.068 in} REAR ABS WHEEL-
Sensor Output Value Inspection SPEED SENSOR
1. Turn the ignition switch off.

CLEARANCE

REAR ABS SENSOR ROTOR

acxuuw00001372
2. Connect the M-MDS to the DLC-2 connector.
3. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Module”.
4. Select “ABS”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “ABS”.
3. Select “DataLogger”.
4. Select the following PIDs using the M-MDS: ac9uuw00000862
• WSPD_LR
(LR ABS wheel-speed sensor)
• WSPD_RR
(RR ABS wheel-speed sensor)
5. Start the engine and drive the vehicle.
6. Verify that the display of the M-MDS shows the same value as the speedometer.
• If there is any malfunction, replace the rear ABS wheel-speed sensor.

04-18–15
1890-1U-06H(04-18).fm 16 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

End Of Sie

COMBINED SENSOR REMOVAL/INSTALLATION

WM: COMBINED SENSOR

id041800817100

Warning
• If the DSC/RSC sensor initialization procedure is not completed, it could result in an unexpected
accident due to the DSC/RSC being inoperative. Therefore, after the combined sensor is replaced,
always perform the DSC/RSC sensor initialization procedure to ensure proper DSC/RSC operation.

Caution
• The internal parts of the combined sensor could be damaged if dropped. Be careful not to drop the
combined sensor. Replace the combined sensor if it is subjected to an impact. Also, do not use an
impact wrench or other similar air tools when removing/installing the sensor.

1. Remove the second-row seat (RH). (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
2. Remove the edge cover. (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
3. Remove the long slider cover. (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
4. Separate the floor carpet at the area shown in the
figure.
REAR HEAT DUCT NO.4
Caution
• When separating the floor carpet, the
wiring harnesses under the floor carpet
could be damaged. Separate the floor
carpet while lifting it so as not to damage CUTTING LINE
the wiring harnesses.

ac9uuw00001271

5. Partially peel back the floor carpet from where it is

separated as shown in the figure. FLOOR COVERING
6. Remove the rear heat duct No.4.
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. After installation, perform the DSC/RSC sensor
initialization procedure. (See 04-18-9 DSC/RSC
SENSOR INITIALIZATION PROCEDURE.)

REAR HEAT DUCT NO.4

ac9uuw00001272

04-18–16
1890-1U-06H(04-18).fm 17 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

7.8—10.8 {80—110, 70—95}

7.8—10.8 {80—110, 70—95} 04-18

7.8—10.8 {80—110, 70—95}

B

N·m {kgf·cm, in·lbf}

ac9uuw00001273

1 Combined sensor cover 3 Combined sensor

2 Combined sensor connector 4 Combined sensor bracket

End Of Sie
COMBINED SENSOR INSPECTION
id041800817200
1. Turn the ignition switch off.
2. Remove the combined sensor installation nut.
3. Connect the M-MDS to the DLC-2 connector.
4. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “ABS”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “ABS”.
3. Select “DataLogger”.
ac9uuw00000862

04-18–17
1890-1U-06H(04-18).fm 18 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

5. Select the following PIDs, then inspect the lateral acceleration speed, longitudinal acceleration speed, roll rate
and yaw rate.
— LAT_ACCL: (lateral acceleration speed)
— ACCLMTR: (longitudinal acceleration speed)
— YAW_RATE: (yaw rate)
— ROLL_RATE (roll rate)
(1) Lateral acceleration speed inspection
1) Verify the LAT_ACCL change when the
combined sensor is tilted to the left and
right.
• If there is any malfunction, replace the
combined sensor.
A
Standard
When the sensor is tilted to the right (A):
LAT_ACCL changes negatively.
When the sensor is tilted to the left (B):
LAT_ACCL changes positively. B
ac9uuw00001331
(2) Longitudinal acceleration speed inspection
1) Verify the ACCLMTR change when the
combined sensor is moved forward and
backward.
• If there is any malfunction, replace the
combined sensor. B

Standard
When the sensor is tilted to forward (A):
ACCLMTR changes negatively.
When the sensor is tilted to backward (B): A
ACCLMTR changes positively.
ac9uuw00001329
(3) Yaw rate inspection
1) Verify the YAW_RATE change when the
combined sensor is rotated to the left and
right. B
• If there is any malfunction, replace the
combined sensor.

Standard
When the sensor is rotated to the right (A): A
YAW_RATE changes positively.
When the sensor is rotated to the left (B):
YAW_RATE changes negatively.
ac9uuw00001330
(4) Roll rate inspection
1) Verify the ROLL_RATE change when the
combined sensor is tilted to the left and
right.
• If there is any malfunction, replace the
combined sensor
A
Standard
When the sensor is tilted to the right (A):
ROLL_RATE changes positively
When the sensor is tilted to the left (B):
ROLL_RATE changes negatively B
ac9uuw00001331
End Of Sie
WM: BRAKE FLUID PRESSURE SENSOR

04-18–18
1890-1U-06H(04-18).fm 19 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

BRAKE FLUID PRESSURE SENSOR INSPECTION
id041800817300

Note
• The brake fluid pressure sensor is integrated into the DSC HU/CM and installed to the brake line of RF—
LR brake system. Therefore, perform the brake fluid pressure sensor inspection with the SST installed to
the brake pipe on the left front wheel.

1. Turn the ignition switch off.

2. Disconnect the brake pipe flare nut area using a
commercially available flare nut wrench.
3. Remove the clamp and disconnect the brake BRAKE PIPE
hose. CLAMP

BRAKE HOSE
04-18

ac9uuw00002141
4. Install the SSTs to the brake pipe as shown in the
49 U043 004A
figure.
5. Bleed the brake line and the SSTs of air. Bleed
the air from the SSTs using bleeder screw A.

49 U043 006 A

49 U043 005
ac9uuw00002142
6. Connect the M-MDS to the DLC-2 connector.
7. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “ABS”.
• When using the PDS (pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “ABS”.
3. Select “DataLogger”.
ac9uuw00000862
8. Select the “MCYLIP” PID.
9. Start the engine.
10. Depress the brake pedal, and confirm that the fluid pressure value of the SST (Gauge) and the value shown on
the M-MDS are equal
• If the fluid pressures are different, replace the DSC/RSC HU/CM. (See 04-18-6 DSC/RSC HU/CM
REMOVAL/INSTALLATION.)
11. After the inspection, remove the SSTs, install the BRAKE PIPE
brake hose, clamp, and brake pipe to the original 12.8—21.6 N·m
positions, and then bleed the air from the brake {131—220 kgf·cm,
line. 114—191 in·lbf}
End Of Sie
WM: TCS OFF SWITCH

ac9uuw00002143

04-18–19
1890-1U-06H(04-18).fm 20 ページ ２００６年１２月１９日　火曜日　午前１１時４４分

DYNAMIC STABILITY CONTROL/ROLL STABILITY CONTROL

TCS OFF SWITCH REMOVAL/INSTALLATION
id041800817400
1. Remove the dashboard under cover (LH). (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
2. Remove the hood release lever. (See 09-14-46 HOOD LATCH AND RELEASE LEVER REMOVAL/
INSTALLATION.)
3. Remove in the order indicated in the table.
TAB
1 TCS OFF switch
(See 04-18-20 TCS OFF Switch Removal Note.) 2
1
2 TCS OFF switch connector

4. Install in the reverse order of removal.

ac9uuw00001274

TCS OFF Switch Removal Note

1. Access the TCS OFF switch from behind of the dashboard, and squeeze the tabs of the switch.
2. Remove the TCS OFF switch from the dashboard.
End Of Sie
TCS OFF SWITCH INSPECTION
id041800817500
1. Remove the TCS OFF switch. (See 04-18-20 TCS OFF SWITCH REMOVAL/INSTALLATION.)
2. Verify that the continuity is as indicated in the
table.
• If not as indicated in the table, replace the F A
TCS OFF switch.

: Bulb : Continuity F E D C B A

Terminal
Condition
A C E F E C
Switch pressed

Switch released
acxuuw00001221
acxuuw00001220

End Of Sie

04-18–20
1890-1U-06H(04-50).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時４６分

TECHNICAL DATA
04-50 TECHNICAL DATA
BRAKES TECHNICAL DATA . . . . . . . . . 04-50–1

End of Toc
BRAKES TECHNICAL DATA
WM: BRAKES

id045000800100

Item Specification
Brake fluid type SAE J1703, FMVSS 116 DOT-3
Brake pedal height (reference value) 206.3 mm {8.122 in}
Brake pedal play 2—5 mm {0.08—0.19 in}
Brake pedal-to-floor clearance (Brake pedal when
97.6 mm {3.84 in} or more
depressed at 147 N {15.0 kgf, 33.0 lbf})
Front disc plate runout limit 0.05 mm {0.002 in} 04-50
Minimum front disc plate thickness 26 mm {1.03 in}
Minimum front disc plate thickness after machining
26.8 mm {1.06 in}
using a brake lathe on-vehicle
Minimum front disc pad thickness 2.0 mm {0.08 in}
Rear disc plate runout limit 0.05 mm {0.002 in}
Minimum rear disc plate thickness 16 mm {0.63 in}
Minimum rear disc plate thickness after machining
16.8 mm {0.66 in}
using a brake lathe on-vehicle
Minimum rear disc pad thickness 2.0 mm {0.08 in}
Parking brake pedal stroke when depressed at 180 N
1—3 notches
{18.4 kgf, 40.5 lbf}
Minimum parking brake shoe thickness 1.0 mm {0.04 in}
Maximum rear disc plate inner diameter 191.0 mm {7.52 in}

Master cylinder fluid pressure

Vacuum amount at o kPa {0 mmHg, 0 inHg}
Pedal force Fluid pressure
200 N {20.4kgf, 44.9lbt} 520 kPa {5.31 kgf/cm2, 75.5 psi} or more

Master cylinder fluid pressure

Vacuum amount at 66.7 kPa {500 mmHg, 19.7 inHg}
Pedal force Fluid pressure
200 N {20.4kgf, 44.9lbt} 9,000 kPa {91.78 kgf/cm2, 1,306 psi} or more

End Of Sie

04-50–1
1890-1U-06H(04-60).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時４７分

SERVICE TOOLS
04-60 SERVICE TOOLS
BRAKES SST . . . . . . . . . . . . . . . . . . . . . 04-60–1

End of Toc
BRAKES SST
WM: BRAKES

id046000800100

49 0221 600C 49 U043 004A 49 U043 006

Disc brake Oil pressure Hose

expand tool gauge (Part of 49
(Part of 49 U043 0A0A)
U043 0A0A)
49 U043 005 49 T033 001A
04-60
Joint Disc brake
(Part of 49 piston stopper —
U043 0A0A)

End Of Sie

04-60–1
1890-1U-06H(05-02).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

TRANSMISSION/TRANSAXLE 05
SECTION

Toc of SCT
ON-BOARD DIAGNOSTIC AUTOMATIC TRANSAXLE
[AW6A-EL, AW6AX-EL] . . . . . 05-02 [AW6A-EL, AW6AX-EL] . . . . 05-17
SYMPTOM AUTOMATIC TRANSAXLE
TROUBLESHOOTING SHIFT MECHANISM . . . . . . . 05-18
[AW6A-EL, AW6AX-EL] . . . . . 05-03 TECHNICAL DATA . . . . . . . . . . 05-50
SERVICE TOOLS . . . . . . . . . . . 05-60
Toc of SCT 05-02
05-02 ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]
AUTOMATIC TRANSAXLE CONTROL DTC P0819 [AW6A-EL, AW6AX-EL] . . . 05-02–43
SYSTEM WIRING DIAGRAM DTC P0882 [AW6A-EL, AW6AX-EL] . . . 05-02–46
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-02–2 DTC P0883 [AW6A-EL, AW6AX-EL] . . . 05-02–48
FOREWORD DTC P0942 [AW6A-EL, AW6AX-EL] . . . 05-02–49
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-02–3 DTC P0961 [AW6A-EL, AW6AX-EL] . . . 05-02–50
AUTOMATIC TRANSAXLE ON-BOARD DTC P0962 [AW6A-EL, AW6AX-EL] . . . 05-02–52
DIAGNOSTIC FUNCTION DTC P0963 [AW6A-EL, AW6AX-EL] . . . 05-02–54
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-02–3 DTC P0973 [AW6A-EL, AW6AX-EL] . . . 05-02–56
DTC Reading Procedure. . . . . . . . . . . . 05-02–3 DTC P0974 [AW6A-EL, AW6AX-EL] . . . 05-02–58
AFTER REPAIR PROCEDURE DTC P0976 [AW6A-EL, AW6AX-EL] . . . 05-02–60
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-02–4 DTC P0977 [AW6A-EL, AW6AX-EL] . . . 05-02–62
DTC TABLE [AW6A-EL, AW6AX-EL] . . . 05-02–5 DTC P0978 [AW6A-EL, AW6AX-EL] . . . 05-02–64
DTC P0220 [AW6A-EL, AW6AX-EL] . . . . 05-02–8 DTC P0979 [AW6A-EL, AW6AX-EL] . . . 05-02–65
DTC P0601 [AW6A-EL, AW6AX-EL] . . . . 05-02–9 DTC P0980 [AW6A-EL, AW6AX-EL] . . . 05-02–67
DTC P0603 [AW6A-EL, AW6AX-EL] . . . . 05-02–10 DTC P0981 [AW6A-EL, AW6AX-EL] . . . 05-02–68
DTC P0604 [AW6A-EL, AW6AX-EL] . . . . 05-02–11 DTC P0982 [AW6A-EL, AW6AX-EL] . . . 05-02–70
DTC P0706 [AW6A-EL, AW6AX-EL] . . . . 05-02–12 DTC P0983 [AW6A-EL, AW6AX-EL] . . . 05-02–72
DTC P0707 [AW6A-EL, AW6AX-EL] . . . . 05-02–13 DTC P0984 [AW6A-EL, AW6AX-EL] . . . 05-02–74
DTC P0708 [AW6A-EL, AW6AX-EL] . . . . 05-02–14 DTC P0985 [AW6A-EL, AW6AX-EL] . . . 05-02–75
DTC P0711 [AW6A-EL, AW6AX-EL] . . . . 05-02–14 DTC P0986 [AW6A-EL, AW6AX-EL] . . . 05-02–77
DTC P0712 [AW6A-EL, AW6AX-EL] . . . . 05-02–16 DTC P0997 [AW6A-EL, AW6AX-EL] . . . 05-02–78
DTC P0713 [AW6A-EL, AW6AX-EL] . . . . 05-02–18 DTC P0998 [AW6A-EL, AW6AX-EL] . . . 05-02–80
DTC P0717 [AW6A-EL, AW6AX-EL] . . . . 05-02–20 DTC P0999 [AW6A-EL, AW6AX-EL] . . . 05-02–82
DTC P0722 [AW6A-EL, AW6AX-EL] . . . . 05-02–22 DTC P1700 [AW6A-EL, AW6AX-EL] . . . 05-02–84
DTC P0727 [AW6A-EL, AW6AX-EL] . . . . 05-02–24 DTC P1719 [AW6A-EL, AW6AX-EL] . . . 05-02–85
DTC P0729 [AW6A-EL, AW6AX-EL] . . . . 05-02–24 DTC P1919 [AW6A-EL, AW6AX-EL] . . . 05-02–86
DTC P0730 [AW6A-EL, AW6AX-EL] . . . . 05-02–26 DTC P2544 [AW6A-EL, AW6AX-EL] . . . 05-02–87
DTC P0731 [AW6A-EL, AW6AX-EL] . . . . 05-02–28 DTC P2757 [AW6A-EL, AW6AX-EL] . . . 05-02–88
DTC P0732 [AW6A-EL, AW6AX-EL] . . . . 05-02–30 DTC P2758 [AW6A-EL, AW6AX-EL] . . . 05-02–90
DTC P0733 [AW6A-EL, AW6AX-EL] . . . . 05-02–32 DTC P2762 [AW6A-EL, AW6AX-EL] . . . 05-02–92
DTC P0734 [AW6A-EL, AW6AX-EL] . . . . 05-02–34 DTC P2763 [AW6A-EL, AW6AX-EL] . . . 05-02–94
DTC P0735 [AW6A-EL, AW6AX-EL] . . . . 05-02–36 DTC P2764 [AW6A-EL, AW6AX-EL] . . . 05-02–96
DTC P0736 [AW6A-EL, AW6AX-EL] . . . . 05-02–38 PID/DATA MONITOR INSPECTION
DTC P0780 [AW6A-EL, AW6AX-EL] . . . . 05-02–40 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-02–98
DTC P0817 [AW6A-EL, AW6AX-EL] . . . . 05-02–41 Simulation Function Procedure . . . . . . 05-02–100

End of Toc
WM: AUTOMATIC TRANSAXLE

05-02–1
1890-1U-06H(05-02).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

AUTOMATIC TRANSAXLE CONTROL SYSTEM WIRING DIAGRAM [AW6A-EL, AW6AX-EL]
id050211800100

SHIFT SOLENOID A
TR SWITCH
(INTEGRATED IN TCM) B5

SHIFT SOLENOID B

B2

VEHICLE SPEED SENSOR

B19
TCC CONTROL
B20
SOLENOID
INPUT/TURBINE SPEED
B9
SENSOR
B12 B4

B13
LINE PRESSURE
CONTROL SOLENOID
B8 B3

TFT SENSOR B1

B7

SHIFT SOLENOID F
UP SWITCH B21
A3
B16
DOWN SWITCH
A4
M RANGE SWITCH
A7
TCM SHIFT SOLENOID C
B11
OTHER MODULE
CAN-H B10
A14
CAN
CAN-L
A6 SHIFT SOLENOID D
B17
OTHER MODULE
B18

SHIFT SOLENOID E
B14

B22
IG1

A11
B+ STARTER LOCK
A5 PCM

A1

GND BACK-UP LIGHT RELAY

A9 A13

ac9uuw00002243
End Of Sie

05-02–2
1890-1U-06H(05-02).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

FOREWORD [AW6A-EL, AW6AX-EL]
id050211800200
• When the customer reports vehicle malfunction, check the malfunction indicator lamp (MIL) indication, AT
warning indication, and diagnostic trouble code (DTC), then diagnose the malfunction according to the
following flowchart.
— If a DTC exists, diagnose the applicable DTC inspection. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-
EL].)
— If a DTC does not exist and the MIL and AT warning lights do not illuminate, diagnose the applicable
symptom troubleshooting. (See 05-03-4 SYMPTOM TROUBLESHOOTING ITEM TABLE [AW6A-EL,
AW6AX-EL].)

CUSTOMER ARRIVES

05-02
WARNING LIGHT* NO WARNING LIGHT*
ON/FLASHING WITH SYMPTOM

CHECK FOR CHECK DTC

PRIORITIZED DTC IGNITION ON TEST, IDLING
TEST
DTC

WITHOUT DTC

DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC) DIAGNOSE BY SYMPTOM
DTC TABLE (SYMPTOM TROUBLESHOOTING)
DTC 1. DIAGNOSTIC INDEX
TROUBLESHOOTING 2. QUICK DIAGNOSIS CHART
FLOW 3. SYMPTOM
TROUBLESHOOTING

ac9uuw00002031

*: Malfunction Indicator Lamp (MIL), AT warning light

End Of Sie
AUTOMATIC TRANSAXLE ON-BOARD DIAGNOSTIC FUNCTION [AW6A-EL, AW6AX-EL]
id050211800300
DTC Reading Procedure
1. Perform necessary vehicle preparation and visual inspection.
2. Connect the M-MDS to the DLC-2.
3. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the "Toolbox" tab.
2. Select "Self Test".
3. Select "Modules".
4. Select "TCM".
• When using the PDS (Pocket PC) DLC-2
1. Select "Module Tests".
2. Select "TCM".
3. Select "Self Test".
ac9uuw00002032
4. Verify the DTC according to the directions on the
screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
5. After completion of repairs, clear all DTCs stored in the TCM. (See 05-02-4 AFTER REPAIR PROCEDURE
[AW6A-EL, AW6AX-EL].)
End Of Sie

05-02–3
1890-1U-06H(05-02).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

AFTER REPAIR PROCEDURE [AW6A-EL, AW6AX-EL]
id050211800400

Caution
• After repairing a malfunction, perform this procedure to verify that the malfunction has been
corrected.
• When this procedure is carried out, be sure to drive the vehicle at lawful speed and pay attention
to the other vehicles.

1. Connect the M-MDS to the vehicle DLC-2.

2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select “Toolbox” tab.
2. Select “Self Test”.
3. Select “Modules”.
4. Select “TCM”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “TCM”.
3. Select “Self Test”.
ac9uuw00002033
3. Verify the DTC according to the directions on the
screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Perform the following trouble code inspections to ensure that the DTC has been resolved:
DTC No. Inspection
i. Start the engine.
P0220, P0727, P1919, ii. Warm up the engine to normal operating temperature.
P2544 iii. Drive the vehicle in D range for 500 ms or more.
iv. Go to Step 6.
P0601, P0603, P0604,
P0780, P0817, P0882,
P0883, P0942, P0961,
P0962, P0963, P0973,
i. Start the engine.
P0974, P0976, P0977,
ii. Warm up the engine and ATX.
P0978, P0979, P0980,
iii. Drive the vehicle in D range and make sure that the gears shift smoothly from 1GR to 6GR.
P0981, P0982, P0983,
iv. Go to Step 6.
P0984, P0985, P0986,
P0997, P0998, P0999,
P1700, P2762, P2763,
P2764
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P0706, P0707, P0708
iii. Depress the brake pedal, and shift the selector lever from P to D for 5 s or more.
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P0711
iii. Drive the vehicle in D range for 15 min or more.
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P0712, P0713
iii. Drive the vehicle in D range for 150 s or more.
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P0717, P0722 iii. Drive the vehicle, two separate times, in D range at 20 km/h {12 mph} or more for 150 s or
more.
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P0729, P0734, P0735
iii. Drive the vehicle in D range, at 40 km/h {25 mph} or more for 2 s or more.
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P0731, P0732
iii. Drive the vehicle in D range, at 10 km/h {6 mph} or more for 2 s or more.
iv. Go to Step 6.

05-02–4
1890-1U-06H(05-02).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC No. Inspection
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P0733
iii. Drive the vehicle in D range, at 20 km/h {12 mph} or more for 2 s or more.
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P0736
iii. Drive the vehicle in R range.
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P0819 iii. Drive the vehicle in M range, and shift the selector lever (operate up and down switches)
between 1GR to 6GR for 10 s or more.
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
iii. Drive the vehicle under the following conditions:
P1719 — Drive in the D range
— Engine speed: 500 rpm or more 05-02
— Accelerator pedal opening angle: 2 % or more
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine and ATX.
P2757 iii. Drive the vehicle in D range and make sure that the gears shift smoothly from 1GR to 6GR
and TCC is operated.
iv. Go to Step 6.
i. Start the engine.
ii. Warm up the engine to normal operating temperature.
P2758 iii. Drive the vehicle in D range and make sure that the gears shift smoothly from 1GR to 6GR
and TCC is no operated.
iv. Go to Step 6.

6. Gradually slow down and stop the vehicle.

7. Make sure that no DTCs occur.
End Of Sie
DTC TABLE [AW6A-EL, AW6AX-EL]
id050211800500

X: Available
AT
Monitor Memory
DTC No. Condition MIL warning DC Page
item function
light
Accelerator pedal position signal (See 05-02-8 DTC P0220
P0220 X X 1 CCM X
error [AW6A-EL, AW6AX-EL])
(See 05-02-9 DTC P0601
P0601 Flash ROM malfunction X X 1 CCM X
[AW6A-EL, AW6AX-EL])
(See 05-02-10 DTC P0603
P0603 EEPROM malfunction X X 1 – X
[AW6A-EL, AW6AX-EL])
(See 05-02-11 DTC P0604
P0604 RAM malfunction X X 1 CCM X
[AW6A-EL, AW6AX-EL])
Transaxle range (TR) switch (See 05-02-12 DTC P0706
P0706 X X 1 Other X
circuit range/performance [AW6A-EL, AW6AX-EL])
Transaxle range (TR) switch (See 05-02-13 DTC P0707
P0707 X X 1 CCM X
circuit low input [AW6A-EL, AW6AX-EL])
Transaxle range (TR) switch (See 05-02-14 DTC P0708
P0708 X X 1 CCM X
circuit high input [AW6A-EL, AW6AX-EL])
Transaxle fluid temperature (TFT) (See 05-02-14 DTC P0711
P0711 X X 1 CCM X
sensor malfunction (stuck) [AW6A-EL, AW6AX-EL])
Transaxle fluid temperature (TFT)
(See 05-02-16 DTC P0712
P0712 sensor circuit malfunction (short X X 1 CCM X
[AW6A-EL, AW6AX-EL])
to ground)
Transaxle fluid temperature (TFT)
(See 05-02-18 DTC P0713
P0713 sensor circuit malfunction (short X X 1 CCM X
[AW6A-EL, AW6AX-EL])
to power/open circuit)

05-02–5
1890-1U-06H(05-02).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

AT
Monitor Memory
DTC No. Condition MIL warning DC Page
item function
light
Input/turbine speed sensor circuit
(See 05-02-20 DTC P0717
P0717 malfunction (open circuit/short X X 1 CCM X
[AW6A-EL, AW6AX-EL])
circuit)
Vehicle speed sensor (VSS)
(See 05-02-22 DTC P0722
P0722 circuit malfunction (open circuit/ X X 1 CCM X
[AW6A-EL, AW6AX-EL])
short circuit)
(See 05-02-24 DTC P0727
P0727 Engine speed signal error X X 1 CCM X
[AW6A-EL, AW6AX-EL])
Gear 6 incorrect (incorrect gear (See 05-02-24 DTC P0729
P0729 X X 1 CCM X
ratio detected) [AW6A-EL, AW6AX-EL])
Gear 1 and engine brake
(See 05-02-26 DTC P0730
P0730 operation incorrect (incorrect gear – X 1 CCM X
[AW6A-EL, AW6AX-EL])
ratio detected)
Gear 1 incorrect (incorrect gear (See 05-02-28 DTC P0731
P0731 X X 1 CCM X
ratio detected) [AW6A-EL, AW6AX-EL])
Gear 2 incorrect (incorrect gear (See 05-02-30 DTC P0732
P0732 X X 1 CCM X
ratio detected) [AW6A-EL, AW6AX-EL])
Gear 3 incorrect (incorrect gear (See 05-02-32 DTC P0733
P0733 X X 1 CCM X
ratio detected) [AW6A-EL, AW6AX-EL])
Gear 4 incorrect (incorrect gear (See 05-02-34 DTC P0734
P0734 X X 1 CCM X
ratio detected) [AW6A-EL, AW6AX-EL])
Gear 5 incorrect (incorrect gear (See 05-02-36 DTC P0735
P0735 X X 1 CCM X
ratio detected) [AW6A-EL, AW6AX-EL])
Gear reverse incorrect (incorrect (See 05-02-38 DTC P0736
P0736 – X 1 – X
gear ratio detected) [AW6A-EL, AW6AX-EL])
Valve control solenoid circuit (See 05-02-40 DTC P0780
P0780 – X 1 CCM X
malfunction (valve stuck) [AW6A-EL, AW6AX-EL])
Starter lock output signal circuit
(See 05-02-41 DTC P0817
P0817 malfunction (open circuit/short – X 1 – X
[AW6A-EL, AW6AX-EL])
circuit)
Manual switch/up switch/down
(See 05-02-43 DTC P0819
P0819 switch circuit malfunction (open – X 1 – X
[AW6A-EL, AW6AX-EL])
circuit/short circuit)
(See 05-02-46 DTC P0882
P0882 TCM B+ low – – 1 CCM X
[AW6A-EL, AW6AX-EL])
(See 05-02-48 DTC P0883
P0883 TCM B+ high – – 1 CCM X
[AW6A-EL, AW6AX-EL])
Valve control solenoid circuit
(See 05-02-49 DTC P0942
P0942 malfunction at D range (valve X X 1 CCM X
[AW6A-EL, AW6AX-EL])
stuck)
Line pressure control solenoid (See 05-02-50 DTC P0961
P0961 X X 1 CCM X
range/performance (stuck) [AW6A-EL, AW6AX-EL])
Line pressure control solenoid
(See 05-02-52 DTC P0962
P0962 circuit malfunction (short to X X 1 CCM X
[AW6A-EL, AW6AX-EL])
ground/open circuit)
Line pressure control solenoid
(See 05-02-54 DTC P0963
P0963 circuit malfunction (short to X X 1 CCM X
[AW6A-EL, AW6AX-EL])
power)
Shift solenoid A circuit malfunction (See 05-02-56 DTC P0973
P0973 X X 1 CCM X
(short to ground) [AW6A-EL, AW6AX-EL])
Shift solenoid A circuit malfunction (See 05-02-58 DTC P0974
P0974 X X 1 CCM X
(short to power/open circuit) [AW6A-EL, AW6AX-EL])
Shift solenoid B circuit malfunction (See 05-02-60 DTC P0976
P0976 – X 1 – X
(short to ground) [AW6A-EL, AW6AX-EL])
Shift solenoid B circuit malfunction (See 05-02-62 DTC P0977
P0977 – X 1 – X
(short to power/open circuit) [AW6A-EL, AW6AX-EL])
Shift solenoid C range/ (See 05-02-64 DTC P0978
P0978 X X 1 CCM X
performance (stuck) [AW6A-EL, AW6AX-EL])

05-02–6
1890-1U-06H(05-02).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

AT
Monitor Memory
DTC No. Condition MIL warning DC Page
item function
light
Shift solenoid C circuit
(See 05-02-65 DTC P0979
P0979 malfunction (short to ground/open X X 1 CCM X
[AW6A-EL, AW6AX-EL])
circuit)
Shift solenoid C circuit (See 05-02-67 DTC P0980
P0980 X X 1 CCM X
malfunction (short to power) [AW6A-EL, AW6AX-EL])
Shift solenoid D range/ (See 05-02-68 DTC P0981
P0981 X X 1 CCM X
performance (stuck) [AW6A-EL, AW6AX-EL])
Shift solenoid D circuit
(See 05-02-70 DTC P0982
P0982 malfunction (short to ground/open X X 1 CCM X
[AW6A-EL, AW6AX-EL])
circuit)
Shift solenoid D circuit (See 05-02-72 DTC P0983
P0983 X X 1 CCM X
malfunction (short to power) [AW6A-EL, AW6AX-EL])
Shift solenoid E range/ (See 05-02-74 DTC P0984
P0984 X X 1 CCM X
performance (stuck) [AW6A-EL, AW6AX-EL])
Shift solenoid E circuit malfunction (See 05-02-75 DTC P0985 05-02
P0985 X X 1 CCM X
(short to ground/open circuit) [AW6A-EL, AW6AX-EL])
Shift solenoid E circuit malfunction (See 05-02-77 DTC P0986
P0986 X X 1 CCM X
(short to power) [AW6A-EL, AW6AX-EL])
Shift solenoid F range/ (See 05-02-78 DTC P0997
P0997 X X 1 CCM X
performance (stuck) [AW6A-EL, AW6AX-EL])
Shift solenoid F circuit malfunction (See 05-02-80 DTC P0998
P0998 X X 1 CCM X
(short to ground/open circuit) [AW6A-EL, AW6AX-EL])
Shift solenoid F circuit malfunction (See 05-02-82 DTC P0999
P0999 X X 1 CCM X
(short to power) [AW6A-EL, AW6AX-EL])
Valve control solenoid circuit
(See 05-02-84 DTC P1700
P1700 malfunction at R range (valve – X 1 – X
[AW6A-EL, AW6AX-EL])
stuck)
Engine torque signal error (See 05-02-85 DTC P1719
P1719 – – 1 CCM X
(inaccurate signal) [AW6A-EL, AW6AX-EL])
Engine coolant temperature signal (See 05-02-86 DTC P1919
P1919 – – 1 CCM X
error [AW6A-EL, AW6AX-EL])
Engine torque signal error (invalid (See 05-02-87 DTC P2544
P2544 X X 1 CCM X
signal) [AW6A-EL, AW6AX-EL])
Torque converter clutch (TCC) (See 05-02-88 DTC P2757
P2757 X X 1 CCM X
stuck off [AW6A-EL, AW6AX-EL])
Torque converter clutch (TCC) (See 05-02-90 DTC P2758
P2758 X X 1 CCM X
stuck on [AW6A-EL, AW6AX-EL])
TCC control solenoid range/ (See 05-02-92 DTC P2762
P2762 X X 1 CCM X
performance (stuck) [AW6A-EL, AW6AX-EL])
TCC control solenoid circuit (See 05-02-94 DTC P2763
P2763 X X 1 CCM X
malfunction (short to power) [AW6A-EL, AW6AX-EL])
TCC control solenoid circuit
(See 05-02-96 DTC P2764
P2764 malfunction (short to ground/open X X 1 CCM X
[AW6A-EL, AW6AX-EL])
circuit)
U0073 CAN BUS OFF (See 09-02L-8 DTC TABLE [MULTIPLEX COMMUNICATION SYSTEM])
TCM cannot receive any signals
U0100 (See 09-02L-8 DTC TABLE [MULTIPLEX COMMUNICATION SYSTEM])
from PCM
TCM cannot receive any signals
U0121 (See 09-02L-8 DTC TABLE [MULTIPLEX COMMUNICATION SYSTEM])
from DSC/RSC HU/CM
TCM cannot receive any signals
U0140 (See 09-02L-8 DTC TABLE [MULTIPLEX COMMUNICATION SYSTEM])
from BCM
Invalid data received from DSC/
U0415 (See 09-02L-8 DTC TABLE [MULTIPLEX COMMUNICATION SYSTEM])
RSC HU/CM (wheel speed)

MIL: Malfunction Indicator Lamp

DC: Drive Cycle
CCM: Comprehensive Component Monitor
X : Available
– : N/A

05-02–7
1890-1U-06H(05-02).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

End Of Sie

DTC P0220 [AW6A-EL, AW6AX-EL]

id050211816500

DTC P0220 Accelerator pedal position signal error

• If the accelerator pedal position signal from the PCM, which is transmitted using the CAN communication,
is invalid and the condition has continued for 500 ms or more.
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Accelerator pedal position sensor malfunction
POSSIBLE
• PCM malfunction
CAUSE
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY DTC Yes Go to the applicable DTC inspection.
• Turn the ignition switch to the LOCK position, (See 01-02-12 DTC TABLE [MZI-3.5].)
then to the ON position. No Go to the next step.
• Verify the DTC in the PCM memory.
• Are any DTCs stored?
4 VERIFY TROUBLESHOOTING OF DTC P0220 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range for 500 ms or
more.
• Is the same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–8
1890-1U-06H(05-02).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0601 [AW6A-EL, AW6AX-EL]
id050211800600

DTC P0601 Flash ROM malfunction

• Flash ROM (in TCM) internal circuit malfunction is detected.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
POSSIBLE
• TCM malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been
05-02
then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0601 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–9
1890-1U-06H(05-02).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0603 [AW6A-EL, AW6AX-EL]
id050211800700

DTC P0603 EEPROM malfunction

• Different numeric values for EEPRROM and RAM (in TCM) are detected.
Diagnostic support note:
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
POSSIBLE
• TCM malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0603 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–10
1890-1U-06H(05-02).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0604 [AW6A-EL, AW6AX-EL]
id050211800800

DTC P0604 RAM malfunction

• RAM (in TCM) read/write error is detected.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
POSSIBLE
• TCM malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been
05-02
then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0604 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–11
1890-1U-06H(05-02).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0706 [AW6A-EL, AW6AX-EL]
id050211800900

DTC P0706 Transaxle range (TR) switch circuit range/performance

• TCM detects stuck TR switch when ignition switch is at ON position.
Diagnostic support note:
• This is continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
POSSIBLE • TR switch malfunction
CAUSE • TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0706 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in each range (P—D).
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–12
1890-1U-06H(05-02).fm 13 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0707 [AW6A-EL, AW6AX-EL]
id050211801000

DTC P0707 Transaxle range (TR) switch circuit low input

• TR switch position voltage input to TCM is less than 0.127 V when ignition switch is at ON position.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
POSSIBLE • TR switch malfunction
CAUSE • TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been
05-02
then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0707 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in each range (P—D).
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–13
1890-1U-06H(05-02).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0708 [AW6A-EL, AW6AX-EL]
id050211801100

DTC P0708 Transaxle range (TR) switch circuit high input

• TR switch position voltage input to TCM is 4.84 V or more when ignition switch is at ON position.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
POSSIBLE • TR switch malfunction
CAUSE • TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0708 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in each range (P—D).
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie
DTC P0711 [AW6A-EL, AW6AX-EL]
id050211801200

DTC P0711 Transaxle fluid temperature (TFT) sensor malfunction (stuck)

• Change in ATF temperature cannot be detected for 15 min or more when driving in D range.
Diagnostic support note:
• This is continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• TFT sensor malfunction
POSSIBLE
• Damaged connector TCM
CAUSE
• TCM malfunction

05-02–14
1890-1U-06H(05-02).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0711 Transaxle fluid temperature (TFT) sensor malfunction (stuck)

TCM
COUPLE COMPONENT CONNECTOR

COUPLE COMPONENT
3
B8 (+)

TFT B7 B8
SENSOR 4

3
B7 (-)

05-02

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 5.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF TFT SENSOR Yes Go to the next step.
CIRCUIT No Replace the TFT sensor, then go to the next step.
• Inspect for resistance between couple (See 05-17-14 TRANSAXLE FLUID TEMPERATURE
component terminals B8 and B7 (wiring (TFT) SENSOR REMOVAL/INSTALLATION [AW6A-EL,
harness-side). AW6AX-EL].)
• Is resistance as shown below?
— ATF temperature 10°C {50°F}: 5.62—7.31
kilohms
— ATF temperature 25°C {77°F}: 3.5 kilohms
— ATF temperature 110°C {230°F}: 0.22—
0.27 kilohms
(See 05-17-13 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION [AW6A-EL, AW6AX-EL].)
5 VERIFY TROUBLESHOOTING OF DTC P0711 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

05-02–15
1890-1U-06H(05-02).fm 16 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

End Of Sie

DTC P0712 [AW6A-EL, AW6AX-EL]

id050211801300

DTC P0712 Transaxle fluid temperature (TFT) sensor circuit malfunction (short to ground)
• If the TCM detects the following condition for 10 s or more, the TCM determines that the TFT sensor circuit
has a malfunction.
— ATF temperature 200 °C {392 °F} or more
Diagnostic support note:
DETECTION • This is continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• TFT sensor malfunction
• Short to ground in wiring harness between TFT sensor and TCM terminal B8
POSSIBLE
• Short to ground in wiring harness between TFT sensor and TCM terminal B7
CAUSE
• Damaged connector TCM
• TCM malfunction

TCM
COUPLE COMPONENT CONNECTOR

COUPLE COMPONENT
3
B8 (+)

TFT B7 B8
SENSOR 4

3
B7 (-)

05-02–16
1890-1U-06H(05-02).fm 17 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 5.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF TFT SENSOR Yes Go to the next step.
CIRCUIT No Replace the TFT sensor, then go to the next step.
• Inspect for resistance between couple (See 05-17-14 TRANSAXLE FLUID TEMPERATURE
component terminals B8 and B7 (wiring (TFT) SENSOR REMOVAL/INSTALLATION [AW6A-EL,
harness-side). AW6AX-EL].)
• Is resistance as shown below?
— ATF temperature 10°C {50°F}: 5.62—7.31
kilohms
— ATF temperature 25°C {77°F}: 3.5 kilohms
— ATF temperature 110°C {230°F}: 0.22—
0.27 kilohms
(See 05-17-13 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION [AW6A-EL, AW6AX-EL].)
5 VERIFY TROUBLESHOOTING OF DTC P0712 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–17
1890-1U-06H(05-02).fm 18 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0713 [AW6A-EL, AW6AX-EL]
id050211801400

DTC P0713 Transaxle fluid temperature (TFT) sensor circuit malfunction (short to power/open circuit)
• If the TCM detects the following condition for 1 s or more, the TCM determines that the TFT sensor circuit
has a malfunction.
— Engine warmed-up
— ATF temperature less than –43 °C {–45.4 °F}
Diagnostic support note:
DETECTION
CONDITION • This is continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• TFT sensor malfunction
• Open circuit in wiring harness between TFT sensor and TCM terminal B8
• Open circuit in wiring harness between TFT sensor and TCM terminal B7
POSSIBLE
• Short to power in wiring harness between TFT sensor and TCM terminal B8
CAUSE
• Short to power in wiring harness between TFT sensor and TCM terminal B7
• Damaged connector TCM
• TCM malfunction

TCM
COUPLE COMPONENT CONNECTOR

COUPLE COMPONENT
3
B8 (+)

TFT B7 B8
SENSOR 4

3
B7 (-)

05-02–18
1890-1U-06H(05-02).fm 19 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 5.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF TFT SENSOR Yes Go to the next step.
CIRCUIT No Replace the TFT sensor, then go to the next step.
• Inspect for resistance between couple (See 05-17-14 TRANSAXLE FLUID TEMPERATURE
component terminals B8 and B7 (wiring (TFT) SENSOR REMOVAL/INSTALLATION [AW6A-EL,
harness-side). AW6AX-EL].)
• Is resistance as shown below?
— ATF temperature 10°C {50°F}: 5.62—7.31
kilohms
— ATF temperature 25°C {77°F}: 3.5 kilohms
— ATF temperature 110°C {230°F}: 0.22—
0.27 kilohms
(See 05-17-13 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION [AW6A-EL, AW6AX-EL].)
5 VERIFY TROUBLESHOOTING OF DTC P0713 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–19
1890-1U-06H(05-02).fm 20 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0717 [AW6A-EL, AW6AX-EL]
id050211801500

DTC P0717 Input/turbine speed sensor circuit malfunction (open circuit/short circuit)
• When all conditions below are satisfied.
— D range of TR switch input
— Driving vehicle at vehicle speed of 20 km/h {12 mph} or more
— Vehicle speed signal 24 pulse input
— Input/turbine speed sensor signal not input
• Normal turbine speed signal is not input.
DETECTION
Diagnostic support note:
CONDITION
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Input/turbine speed sensor malfunction
• Open circuit between input/turbine speed sensor terminal B and TCM terminal B12
• Open circuit between input/turbine speed sensor terminal A and TCM terminal B13
• Short to ground in wiring harness between input/turbine speed sensor terminal B and TCM terminal B12
POSSIBLE
• Short to ground in wiring harness between input/turbine speed sensor terminal A and TCM terminal B13
CAUSE
• Short to power in wiring harness between input/turbine speed sensor terminal B and TCM terminal B12
• Short to power in wiring harness between input/turbine speed sensor terminal A and TCM terminal B13
• Damaged connector between input/turbine speed sensor and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6 7
B12 (+)
5
B

INPUT/TURBINE 4
SPEED SENSOR
A
5 3
6 7
B13 (-)

COUPLE COMPONENT CONNECTOR

INPUT/TURBINE SPEED SENSOR
WIRING HARNESS-SIDE CONNECTOR

B A
B12 B13

05-02–20
1890-1U-06H(05-02).fm 21 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT CONTINUITY OF INPUT/TURBINE Yes Go to go to Step 8.
SPEED SENSOR CIRCUIT No Go to the next step.
• Inspect for continuity between the couple
component terminals B12 and B13 (wiring
harness-side).
• Is there continuity?
5 INSPECT TERMINAL INPUT/TURBINE SPEED Yes Go to the next step.
SENSOR FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the input/turbine speed sensor
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminals (wiring harness-side) and
input/turbine speed sensor terminals (wiring
wiring harness-side).
— Terminal B12 and terminal B
— Terminal B13 and terminal A
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO CIRCUIT next step.
• Inspect for continuity between couple No Replace the input/turbine speed sensor, then go to the next
component terminals (wiring harness-side). step.
— Terminal B12 and all terminals except B12/ (See 05-17-18 INPUT/TURBINE SPEED SENSOR
B13 (wiring harness-side). REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
— Terminal B13 and all terminals except B12/
B13 (wiring harness-side).
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P0717 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie

05-02–21
1890-1U-06H(05-02).fm 22 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0722 [AW6A-EL, AW6AX-EL]
id050211801600

DTC P0722 Vehicle speed sensor (VSS) circuit malfunction (open circuit/short circuit)
• When all conditions below are satisfied.
— D range of TR switch input
— Driving vehicle at vehicle speed of 20 km/h {12 mph} or more
— Turbine speed signal 16 pulse input
— VSS signal not input
• Normal vehicle speed signal is not input for 0.1 s or more.
DETECTION
Diagnostic support note:
CONDITION
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• VSS malfunction
• Open circuit between VSS terminal B and TCM terminal B19
• Open circuit between VSS terminal A and TCM terminal B20
• Short to ground in wiring harness between VSS terminal B and TCM terminal B19
POSSIBLE
• Short to ground in wiring harness between VSS terminal A and TCM terminal B20
CAUSE
• Short to power in wiring harness between VSS terminal B and TCM terminal B19
• Short to power in wiring harness between VSS terminal A and TCM terminal B20
• Damaged connector between VSS and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6 7
B19 (+)
5
B

VSS 4

A
5 3
6 7
B20 (-)

COUPLE COMPONENT CONNECTOR

VSS WIRING HARNESS-SIDE CONNECTOR

B19 B20
B A

05-02–22
1890-1U-06H(05-02).fm 23 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT CONTINUITY OF VSS CIRCUIT Yes Go to go to Step 8.
• Inspect for continuity between the couple No Go to the next step.
component terminals B19 and B20 (wiring
harness-side).
• Is there continuity?
5 INSPECT TERMINAL VSS FOR POOR Yes Go to the next step.
CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the VSS connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminals (wiring harness-side) and
VSS terminals (wiring harness-side).
— Terminal B19 and terminal B
— Terminal B20 and terminal A
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO CIRCUIT next step.
• Inspect for continuity between couple No Inspect the coupler component.
component terminals (wiring harness-side). • If the coupler component is normal, replace the
— Terminal B19 and all terminals except B19/ automatic transaxle, then go to the next step.
B20 (wiring harness-side). (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
— Terminal B20 and all terminals except B19/ INSTALLATION [AW6A-EL, AW6AX-EL].)
B20 (wiring harness-side).
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P0722 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–23
1890-1U-06H(05-02).fm 24 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0727 [AW6A-EL, AW6AX-EL]
id050211816400

DTC P0727 Engine speed signal error

• If the engine speed signal from the PCM, which is transmitted using the CAN communication, is invalid and
the condition has continued for 500 ms or more.
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• CKP sensor malfunction
POSSIBLE
• PCM malfunction
CAUSE
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY DTC Yes Go to the applicable DTC inspection.
• Turn the ignition switch to the LOCK position, (See 01-02-12 DTC TABLE [MZI-3.5].)
then to the ON position. No Go to the next step.
• Verify the DTC in the PCM memory.
• Are any DTCs stored?
4 VERIFY TROUBLESHOOTING OF DTC P0727 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range for 500 ms or
more.
• Is the same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie
DTC P0729 [AW6A-EL, AW6AX-EL]
id050211801700

DTC P0729 Gear 6 incorrect (incorrect gear ratio detected)

• Incorrect gear ratio detected when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 20 °C {68 °F} or more
— Driving in 6GR in D range
— Engine running
— Accelerator opening angle 10% or more
DETECTION — Vehicle speed signal normal
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.

05-02–24
1890-1U-06H(05-02).fm 25 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0729 Gear 6 incorrect (incorrect gear ratio detected)
• ATF level low
• Deteriorated ATF
• Shift solenoid C stuck
• Shift solenoid E stuck
• Line pressure control solenoid stuck
POSSIBLE
• Line pressure low
CAUSE
• B1 brake slipping
• C2 clutch slipping
• Control valve stuck
• Oil pump malfunction
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded? 05-02
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 8.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
7 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?

05-02–25
1890-1U-06H(05-02).fm 26 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
8 VERIFY TROUBLESHOOTING OF DTC P0729 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle under the following conditions
at least 12 times for more than 1 s:
— ATF temperature (TFT PID): 20 °C {68 °F}
or more
— Drive in the D range, 6GR
— Accelerator opening angle (THOP PID):
10% or more
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie
DTC P0730 [AW6A-EL, AW6AX-EL]
id050211801800

DTC P0730 Gear 1 and engine brake operation incorrect (incorrect gear ratio detected)
• Engine braking is detected to be not operating when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 20 °C {68 °F} or more
— Driving in 1GR in M range
— Engine running
— Accelerator opening angle 10% or more
DETECTION — Vehicle speed signal normal
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL does not illuminate if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
• Shift solenoid A stuck
• Shift solenoid B stuck
• Shift solenoid D stuck
• Shift solenoid E stuck
POSSIBLE • Shift solenoid F stuck
CAUSE • Line pressure control solenoid stuck
• Line pressure low
• C1 clutch slipping
• B2 brake slipping
• Control valve stuck
• Oil pump malfunction
• TCM malfunction

05-02–26
1890-1U-06H(05-02).fm 27 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
05-02
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 8.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
7 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
8 VERIFY TROUBLESHOOTING OF DTC P0730 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle under the following conditions
at least 12 times for more than 1 s:
— ATF temperature (TFT PID):20 °C {68 °F} or
more
— Drive in the M range, 1GR
— Accelerator opening angle (THOP PID):10%
or more
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–27
1890-1U-06H(05-02).fm 28 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0731 [AW6A-EL, AW6AX-EL]
id050211801900

DTC P0731 Gear 1 incorrect (incorrect gear ratio detected)

• Incorrect gear ratio detected when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 20 °C {68 °F} or more
— Driving in 1GR in D range
— Engine running
— Accelerator opening angle 10% or more
DETECTION — Vehicle speed signal normal
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
• Shift solenoid D stuck
• Shift solenoid E stuck
• Shift solenoid F stuck
POSSIBLE • Line pressure control solenoid stuck
CAUSE • Line pressure low
• C1 clutch slipping
• One-way clutch slipping
• Control valve stuck
• Oil pump malfunction
• TCM malfunction

05-02–28
1890-1U-06H(05-02).fm 29 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
05-02
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 8.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
7 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
8 VERIFY TROUBLESHOOTING OF DTC P0731 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle under the following conditions
at least 12 times for more than 1 s:
— ATF temperature (TFT PID): 20 °C {68 °F}
or more
— Drive in the D range, 1GR
— Accelerator opening angle (THOP PID):
10% or more
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–29
1890-1U-06H(05-02).fm 30 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0732 [AW6A-EL, AW6AX-EL]
id050211802000

DTC P0732 Gear 2 incorrect (incorrect gear ratio detected)

• Incorrect gear ratio detected when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 20 °C {68 °F} or more
— Driving in 2GR in D range
— Engine running
— Accelerator opening angle 10% or more
DETECTION — Vehicle speed signal normal
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
• Shift solenoid D stuck
• Shift solenoid E stuck
• Line pressure control solenoid stuck
POSSIBLE
• Line pressure low
CAUSE
• C1 clutch slipping
• B1 brake slipping
• Control valve stuck
• Oil pump malfunction
• TCM malfunction

05-02–30
1890-1U-06H(05-02).fm 31 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
05-02
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 8.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
7 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
8 VERIFY TROUBLESHOOTING OF DTC P0732 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle under the following conditions
at least 12 times for more than 1 s:
— ATF temperature (TFT PID): 20 °C {68 °F}
or more
— Drive in the D range, 2GR
— Accelerator opening angle (THOP PID):
10% or more
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–31
1890-1U-06H(05-02).fm 32 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0733 [AW6A-EL, AW6AX-EL]
id050211802100

DTC P0733 Gear 3 incorrect (incorrect gear ratio detected)

• Incorrect gear ratio detected when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 20 °C {68 °F} or more
— Driving in 3GR in D range
— Engine running
— Accelerator opening angle 10% or more
DETECTION — Vehicle speed signal normal
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
• Shift solenoid D stuck
• Shift solenoid F stuck
• Line pressure control solenoid stuck
POSSIBLE
• Line pressure low
CAUSE
• C1 clutch slipping
• C3 clutch slipping
• Control valve stuck
• Oil pump malfunction
• TCM malfunction

05-02–32
1890-1U-06H(05-02).fm 33 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
05-02
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 8.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
7 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
8 VERIFY TROUBLESHOOTING OF DTC P0733 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle under the following conditions
at least 12 times for more than 1 s:
— ATF temperature (TFT PID): 20 °C {68 °F}
or more
— Drive in the D range, 3GR
— Accelerator opening angle (THOP PID):
10% or more
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–33
1890-1U-06H(05-02).fm 34 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0734 [AW6A-EL, AW6AX-EL]
id050211802200

DTC P0734 Gear 4 incorrect (incorrect gear ratio detected)

• Incorrect gear ratio detected when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 20 °C {68 °F} or more
— Driving in 4GR in D range
— Engine running
— Accelerator opening angle 10% or more
DETECTION — Vehicle speed signal normal
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
• Shift solenoid E stuck
• Shift solenoid F stuck
• Line pressure control solenoid stuck
POSSIBLE
• Line pressure low
CAUSE
• C1 clutch slipping
• C2 clutch slipping
• Control valve stuck
• Oil pump malfunction
• TCM malfunction

05-02–34
1890-1U-06H(05-02).fm 35 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
05-02
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 8.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
7 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
8 VERIFY TROUBLESHOOTING OF DTC P0734 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle under the following conditions
at least 12 times for more than 1 s:
— ATF temperature (TFT PID): 20 °C {68 °F}
or more
— Drive in the D range, 4GR
— Accelerator opening angle (THOP PID):
10% or more
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–35
1890-1U-06H(05-02).fm 36 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0735 [AW6A-EL, AW6AX-EL]
id050211802300

DTC P0735 Gear 5 incorrect (incorrect gear ratio detected)

• Incorrect gear ratio detected when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 20 °C {68 °F} or more
— Driving in 5GR in D range
— Engine running
— Accelerator opening angle 10% or more
DETECTION — Vehicle speed signal normal
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
• Shift solenoid C stuck
• Shift solenoid F stuck
• Line pressure control solenoid stuck
POSSIBLE
• Line pressure low
CAUSE
• C2 clutch slipping
• C3 clutch slipping
• Control valve stuck
• Oil pump malfunction
• TCM malfunction

05-02–36
1890-1U-06H(05-02).fm 37 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
05-02
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 8.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
7 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
8 VERIFY TROUBLESHOOTING OF DTC P0735 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle under the following conditions
at least 12 times for more than 1 s:
— ATF temperature (TFT PID): 20 °C {68 °F}
or more
— Drive in the D range, 5GR
— Accelerator opening angle (THOP PID):
10% or more
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–37
1890-1U-06H(05-02).fm 38 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0736 [AW6A-EL, AW6AX-EL]
id050211802400

DTC P0736 Gear reverse incorrect (incorrect gear ratio detected)

• Incorrect gear ratio detected when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 20 °C {68 °F} or more
— Driving in R position
— Engine running
— Accelerator opening angle 10% or more
DETECTION
— Vehicle speed signal normal
CONDITION
Diagnostic support note:
• The MIL does not illuminate if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
• Shift solenoid C stuck
• Shift solenoid D stuck
• Shift solenoid E stuck
• Shift solenoid F stuck
POSSIBLE
• Line pressure control solenoid stuck
CAUSE
• Line pressure low
• C3 clutch slipping
• B2 brake slipping
• Control valve stuck
• Oil pump malfunction
• TCM malfunction

05-02–38
1890-1U-06H(05-02).fm 39 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
05-02
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 8.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
7 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
8 VERIFY TROUBLESHOOTING OF DTC P0736 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle under the following conditions
at least 12 times for more than 1 s:
— ATF temperature (TFT PID): 20 °C {68 °F}
or more
— Drive in the R position
— Accelerator opening angle (THOP PID):
10% or more
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–39
1890-1U-06H(05-02).fm 40 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0780 [AW6A-EL, AW6AX-EL]
id050211802500

DTC P0780 Valve control solenoid circuit malfunction (valve stuck)

• Irregular shift control detected when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 65 °C {149 °F} or more
— Engine running
— Driving in D range
— Counter drive gear (output) revolution speed 300 rpm or more (VSS)
DETECTION
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Shift solenoid A stuck
• Shift solenoid B stuck
• Shift solenoid C stuck
• Shift solenoid D stuck
POSSIBLE
• Shift solenoid E stuck
CAUSE
• Shift solenoid F stuck
• Line pressure control solenoid stuck
• Control valve stuck
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT SOLENOID VALVE Yes Go to the next step.
• Inspect the solenoid valve. No Replace the control valve body, then go to the next step.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
4 VERIFY TROUBLESHOOTING OF DTC P0780 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–40
1890-1U-06H(05-02).fm 41 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0817 [AW6A-EL, AW6AX-EL]
id050211802600

DTC P0817 Starter lock output signal circuit malfunction (open circuit/short circuit)
• Any of the following conditions are met when ignition switch is at ON position:
— 0 V detected at TCM terminal A5 when in D range or R position
— 12 V detected at TCM terminal A5 when in P or N position
Diagnostic support note:
DETECTION
CONDITION • The MIL does not illuminate if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit between PCM terminal 1F and TCM terminal A5
• Short to ground in wiring harness between PCM terminal 1F and TCM terminal A5
POSSIBLE • Short to power in wiring harness between PCM terminal 1F and TCM terminal A5
CAUSE • PCM malfunction
• Damaged connector between PCM and TCM
• TCM malfunction
TCM 05-02

3
PCM
4
6 5
7 8 9
1F A5

PCM
WIRING HARNESS-SIDE CONNECTOR TCM WIRING HARNESS-SIDE CONNECTOR

1BQ 1BL 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1F 1A

1BN 1BI 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1H 1C
A5

1BR 1BM 1BH 1BD 1AZ 1AV 1AR AN1 1AJ 1AF 1AB 1X 1T 1P 1L 1G 1B

1BO 1BJ 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1I 1D

1BP 1BK 1J 1E

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?

05-02–41
1890-1U-06H(05-02).fm 42 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
3 INSPECT VOLTAGE OF STARTER LOCK Yes Go to go to Step 5.
OUTPUT SIGNAL CIRCUIT No Go to the next step.
• Turn the ignition switch to the ON position
(engine off).
• Shift the selector lever to P or N position.
• Inspect for voltage TCM connector terminal A5
(wiring harness-side).
• Is the voltage 0 V?
4 INSPECT TCM CONNECTOR FOR POOR Yes Go to Step 10.
CONNECTION No Replace the couple component, then go to Step 10.
• Disconnect the TCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
5 INSPECT VOLTAGE OF STARTER LOCK Yes Go to go to Step 10.
OUTPUT SIGNAL CIRCUIT No Go to the next step.
• Shift the selector lever to D range or R position.
• Inspect for voltage TCM connector terminal A5
(wiring harness-side).
• Is the voltage B+?
6 INSPECT PCM FOR POOR CONNECTION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No Replace the couple component, then go to Step 10.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
7 INSPECT STARTER LOCK OUTPUT SIGNAL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the harness, then go to Step 10.
• Inspect for continuity between TCM connector
terminal A5 and PCM terminal 1F (wiring
harness-side).
• Is there continuity?
8 INSPECT STARTER LOCK OUTPUT SIGNAL Yes Repair or replace the harness, then go to Step 10.
CIRCUIT FOR SHORT TO GROUND No Go to the next step.
• Inspect for continuity between PCM terminal
1F (wiring harness-side) and body ground.
• Is there continuity?
9 INSPECT STARTER LOCK OUTPUT SIGNAL Yes Go to the next step.
CIRCUIT FOR SHORT TO POWER No Repair or replace the wiring harness, then go to the next
• Turn the ignition switch to the ON position step.
(engine off).
• Inspect the voltage at PCM terminal 1F (wiring
harness-side).
• Is the voltage 0 V?
10 VERIFY TROUBLESHOOTING OF DTC P0817 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range.
• Is the same DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–42
1890-1U-06H(05-02).fm 43 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0819 [AW6A-EL, AW6AX-EL]
id050211802700

DTC P0819 Manual switch/up switch/down switch circuit malfunction (open circuit/short circuit)
• Any of the following conditions are detected for 10 s or more when engine is running:
— 5 V detected at TCM terminals A7 when in any position except D or M range.
— 0 V detected at TCM terminal A7 when 5 V are input to TCM terminal A3 or A4.
Diagnostic support note:
DETECTION
CONDITION • The MIL does not illuminate if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• M range switch malfunction
• Up switch malfunction
• Down switch malfunction.
• Open circuit in wiring harness between selector lever component terminal A and TCM terminal A3
• Open circuit in wiring harness between selector lever component terminal B and TCM terminal A4
POSSIBLE • Open circuit in wiring harness between selector lever component terminal C and TCM terminal A7
CAUSE • Open circuit in wiring harness between selector lever component terminal D and ground 05-02
• Short to ground in wiring harness between selector lever component terminal A and TCM terminal A3
• Short to ground in wiring harness between selector lever component terminal B and TCM terminal A4
• Short to ground in wiring harness between selector lever component terminal C and TCM terminal A7
• Damaged connector between selector lever component and TCM
• TCM malfunction
7 TCM
SELECTOR LEVER
COMPONENT
UP
SWITCH 5 6 9 3 4
A A3

DOWN
SWITCH 5 6 9 3 4
B A4

M RANGE
5 SWITCH
5 6 9 3 4
D C A7
8

SELECTOR LEVER COMPONENT TCM WIRING HARNESS-SIDE CONNECTOR

WIRING HARNESS-SIDE CONNECTOR

C A
A3 A4 A7
D B

05-02–43
1890-1U-06H(05-02).fm 44 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT VOLTAGE OF M RANGE SWITCH, UP Yes Go to go to Step 10.
SWITCH, AND DOWN SWITCH CIRCUIT No Go to the next step.
• Turn the ignition switch to the ON position.
(engine off)
• Shift the selector lever to any except M range.
• Inspect for voltage between TCM connector
terminals (wiring harness-side)
— Terminal A7 and ground (M range switch)
— Terminal A3 and ground (up switch)
— Terminal A4 and ground (down switch)
• Is the voltage B+?
4 INSPECT TCM CONNECTOR FOR POOR Yes Go to the next step.
CONNECTION No Replace the couple component, then go to Step 10.
• Disconnect the TCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
5 INSPECT SELECTOR LEVER COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 10.
• Disconnect the selector lever component
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT M RANGE SWITCH, UP SWITCH, AND Yes Repair or replace the harness, then go to Step 10.
DOWN SWITCH CIRCUIT FOR SHORT TO No Go to the next step.
GROUND
• Inspect for continuity between selector lever
component terminals (wiring harness-side) and
body ground.
— Terminal C and body ground (M range
switch)
— Terminal A and body ground (up switch)
— Terminal B and body ground (down switch)
• Is there continuity?
7 INSPECT M RANGE SWITCH, UP SWITCH, AND Yes Go to the next step.
DOWN SWITCH No Replace the selector lever, then go to Step 10.
• Inspect the M range switch, up switch, and (See 05-18-8 SELECTOR LEVER COMPONENT
down switch. REMOVAL/INSTALLATION.)
(See 05-18-7 SELECTOR LEVER
COMPONENT INSPECTION.)
• Are the switches normal?
8 INSPECT M RANGE SWITCH, UP SWITCH, AND Yes Go to the next step.
DOWN SWITCH CIRCUIT FOR OPEN CIRCUIT No Repair or replace the harness, then go to Step 10.
• Inspect for continuity between selector lever
component terminal D (wiring harness-side)
and body ground.
• Is there continuity?

05-02–44
1890-1U-06H(05-02).fm 45 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
9 INSPECT M RANGE SWITCH, UP SWITCH, AND Yes Go to the next step.
DOWN SWITCH CIRCUIT FOR OPEN CIRCUIT No Repair or replace the harness, then go to the next step.
• Inspect for continuity between TCM connector
terminals and selector lever component
terminals (wiring harness-side).
— Terminal A7 and terminal C (M range switch)
— Terminal A3 and terminal A (up switch)
— Terminal A4 and terminal B (down switch)
• Is there continuity?
10 VERIFY TROUBLESHOOTING OF DTC P0819 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in M range, and change gears
by shifting the selector lever (operating the up
and down switches). 05-02
• Is the same DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–45
1890-1U-06H(05-02).fm 46 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0882 [AW6A-EL, AW6AX-EL]
id050211802800

DTC P0882 TCM B+ low

• Voltage of less than 9 V detected at TCM terminals A1 and A11 when engine is running.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL does not illuminate if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light not illuminates.
• The DTC is stored in the TCM memory.
• Melted METER 10 A fuse
• Melted ENGINE 20 A fuse
• Open circuit in wiring harness between ENGINE 20 A fuse and TCM terminal A1
• Open circuit in wiring harness between METER IG 15 A fuse and TCM terminal A11
• Open circuit in wiring harness between TCM terminal A9 and body ground
POSSIBLE
• Short to ground in wiring harness between ENGINE 20 A fuse and TCM terminal A1
CAUSE
• Short to ground in wiring harness between ROOM 15 A fuse and TCM terminal A11
• Poor connection of TCM connector
• Poor connection of BCM connector
• TCM malfunction
• BCM malfunction
B+ IG1

TCM
ENGINE
20 A METER 10 A
FUSE FUSE BCM
3 7 7 4 8
3
4A 2F A11

5 6
4 8
5 6
A1

8
9
A9

TCM WIRING HARNESS-SIDE

CONNECTOR BCM WIRING HARNESS-SIDE
CONNECTOR

A1
2O 2M 2K 2I 2G 2E 2C 2A 4E 4C 4A
2P 2N 2L 2J 2H 2F 2D 2B 4F 4D 4B
A11
A9

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?

05-02–46
1890-1U-06H(05-02).fm 47 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
3 INSPECT FUSE Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No • If fuse has been melted, go to the next step.
• Inspect METER 10 A fuse and ENGINE 20 A • If fuse is not installed correctly, install it correctly, then
fuse for malfunction. go to Step 10.
• Is it normal?
4 INSPECT VOLTAGE OF POWER SUPPLY Yes Go to go to Step 8.
CIRCUIT No Go to the next step.
• Turn the ignition switch to the ON position
(engine off).
• Inspect for voltage TCM connector terminal A1
and A11 (wiring harness-side).
• Is the voltage B+?
5 INSPECT POWER SUPPLY CIRCUIT FOR Yes Repair or replace the wiring harness and install new fuse,
SHORT TO GROUND then go to Step 10.
• Disconnect the positive battery cable. No Go to the next step.
• Inspect for continuity between the fuse
terminals and body ground.
— METER 10 A fuse terminal and body 05-02
ground
— ENGINE 20 A fuse terminal and body
ground
• Is there continuity?
6 INSPECT POWER SUPPLY CIRCUIT FOR OPEN Yes Go to Step 9.
CIRCUIT No Repair or replace the harness and BCM, then go to Step
• Inspect for continuity between TCM connector 10.
terminals and fuse terminals (wiring harness-
side).
— TCM terminal A1 and BCM terminal 2F
— BCM terminal 4A and ENGINE 20 A fuse
— TCM terminal A11 and METER 10 A fuse
• Is there continuity?
7 INSPECT BCM CONNECTOR FOR POOR Yes Go to the next step.
CONNECTION No Replace the couple component, then go to Step 10.
• Disconnect the BCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
8 INSPECT TCM CONNECTOR FOR POOR Yes Go to the next step.
CONNECTION No Replace the couple component, then go to Step 10.
• Disconnect the TCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
9 INSPECT GROUND CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the harness, then go to the next step.
• Inspect for continuity between TCM connector
terminal A9 (wiring harness-side) and body
ground.
• Is there continuity?
10 VERIFY TROUBLESHOOTING OF DTC P0882 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Start the engine and warm it up completely.
• Is the same DTC present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–47
1890-1U-06H(05-02).fm 48 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0883 [AW6A-EL, AW6AX-EL]
id050211802900

DTC P0883 TCM B+ high

• Voltage of 18 V or more detected at TCM terminals A1 and A11 when engine is running.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL does not illuminate if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light not illuminates.
• The DTC is stored in the TCM memory.
POSSIBLE • Generator malfunction
CAUSE • TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY DTC Yes Go to the applicable DTC inspection.
• Turn the ignition switch to the LOCK position, (See 01-02-12 DTC TABLE [MZI-3.5].)
then to the ON position. No Go to the next step.
• Verify the DTC in the PCM memory.
• Are DTC P2504 output?
4 VERIFY TROUBLESHOOTING OF DTC P0883 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Start the engine and warm it up completely.
• Is the same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–48
1890-1U-06H(05-02).fm 49 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0942 [AW6A-EL, AW6AX-EL]
id050211803000

DTC P0942 Valve control solenoid circuit malfunction at D range (valve stuck)
• Difference of less than 150 rpm between engine and turbine speeds detected when following conditions
are satisfied while driving:
Monitoring condition:
— Engine running
— Driving in D range
— Counter drive gear (output) revolution speed500 rpm or more (VSS)
DETECTION
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Shift solenoid A stuck
• Shift solenoid B stuck
POSSIBLE • Shift solenoid C stuck 05-02
CAUSE • C1 clutch slipping
• Control valve stuck
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 6.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 6.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
4 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go the Step 6.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
5 INSPECT SOLENOID VALVE Yes Go to the next step.
• Inspect the solenoid valve. No Replace the control valve body, then go to the next step.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
6 VERIFY TROUBLESHOOTING OF DTC P0942 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie

05-02–49
1890-1U-06H(05-02).fm 50 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0961 [AW6A-EL, AW6AX-EL]
id050211803100

DTC P0961 Line pressure control solenoid range/performance (stuck)

• Feedback current corresponding to solenoid current command value is irregular when engine is running.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
POSSIBLE
• Line pressure control solenoid stuck
CAUSE
• Control valve stuck
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT [AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION [AW6A-EL, AW6AX-EL].)
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM TEST • Any ranges: Replace the ATX, then go the next step.
[AW6A-EL, AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT LINE PRESSURE CONTROL Yes Go to the next step.
SOLENOID No Replace the control valve body.
• Inspect the line pressure control solenoid. (See 05-17-42 CONTROL VALVE BODY REMOVAL/
(See 05-17-21 SOLENOID VALVE INSTALLATION [AW6A-EL, AW6AX-EL].)
INSPECTION [AW6A-EL, AW6AX-EL].)
• Is it normal?

05-02–50
1890-1U-06H(05-02).fm 51 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
7 VERIFY TROUBLESHOOTING OF DTC P0961 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie
05-02

05-02–51
1890-1U-06H(05-02).fm 52 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0962 [AW6A-EL, AW6AX-EL]
id050211803200

DTC P0962 Line pressure control solenoid circuit malfunction (short to ground/open circuit)
• Open or short circuit in line pressure control solenoid signal system (The solenoid circuit current value input
to the TCM is continuously less than 23 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit between line pressure control solenoid terminal B and TCM terminal B3
• Open circuit between line pressure control solenoid terminal A and TCM terminal B1
• Short to ground in wiring harness between line pressure control solenoid terminal B and TCM terminal B3
POSSIBLE
• Short to ground in wiring harness between line pressure control solenoid terminal A and TCM terminal B1
CAUSE
• Line pressure control solenoid malfunction
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6 7
B3 (+)
5
B

LINE PRESSURE 4
CONTROL SOLENOID
A
5 3
6 7
B1 (-)

COUPLE COMPONENT CONNECTOR

LINE PRESSURE CONTROL SOLENOID
WIRING HARNESS-SIDE CONNECTOR

B A

B1 B3

05-02–52
1890-1U-06H(05-02).fm 53 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF LINE PRESSURE Yes Go to go to Step 8.
CONTROL SOLENOID CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B3 and B1 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL LINE PRESSURE Yes Go to the next step.
CONTROL SOLENOID FOR POOR No Replace the couple component, then go to Step 8.
CONNECTION
• Disconnect the line pressure control solenoid
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminals and line pressure control
solenoid terminals (wiring harness-side).
— Terminal B3 and terminal B
— Terminal B1 and terminal A
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO GROUND next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B3 and all terminals except B3/B1 INSTALLATION [AW6A-EL, AW6AX-EL].)
— Terminal B1 and all terminals except B3/B1
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P0962 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie

05-02–53
1890-1U-06H(05-02).fm 54 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0963 [AW6A-EL, AW6AX-EL]
id050211803300

DTC P0963 Line pressure control solenoid circuit malfunction (short to power)
• Short circuit in line pressure control solenoid signal system (The solenoid circuit current value input to the
TCM is continuously more than 1,333 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Short to power in wiring harness between line pressure control solenoid terminal B and TCM terminal B3
• Short to power in wiring harness between line pressure control solenoid terminal A and TCM terminal B1
POSSIBLE
• Line pressure control solenoid malfunction
CAUSE
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6
B3 (+)
5
B

LINE PRESSURE 4
CONTROL SOLENOID
A
5 3
6
B1 (-)

COUPLE COMPONENT CONNECTOR

LINE PRESSURE CONTROL SOLENOID
WIRING HARNESS-SIDE CONNECTOR

B A

B1 B3

05-02–54
1890-1U-06H(05-02).fm 55 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF LINE PRESSURE Yes Go to go to Step 7.
CONTROL SOLENOID CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B3 and B1 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL LINE PRESSURE Yes Go to the next step.
CONTROL SOLENOID FOR POOR No Replace the couple component, then go to Step 7.
CONNECTION
• Disconnect the line pressure control solenoid
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO POWER next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B3 and all terminals except B3/B1 INSTALLATION [AW6A-EL, AW6AX-EL].)
— Terminal B1 and all terminals except B3/B1
• Is there continuity?
7 VERIFY TROUBLESHOOTING OF DTC P0963 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–55
1890-1U-06H(05-02).fm 56 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0973 [AW6A-EL, AW6AX-EL]
id050211803400

DTC P0973 Shift solenoid A circuit malfunction (short to ground)

• Short to ground in shift solenoid A signal system (The solenoid remains off continuously for 100 ms or
more even if the TCM sends a solenoid on command).
Diagnostic support note:
DETECTION • This is continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Short to ground in wiring harness between shift solenoid A terminal A and TCM terminal B5
POSSIBLE • Shift solenoid A malfunction
CAUSE • Damaged connector between shift solenoid A and TCM
• TCM malfunction
TCM

COUPLE COMPONENT
3
6 7
B5
5
4 A

SHIFT SOLENOID A

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID A WIRING

HARNESS-SIDE CONNECTOR

A
B5

05-02–56
1890-1U-06H(05-02).fm 57 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID A Yes Go to go to Step 7.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminal B5 (wiring harness-side)
and ground.
• Is resistance within 11—15 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID A FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 7.
• Disconnect the shift solenoid A connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO GROUND next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminal B5 and all terminals (See 05-17-42 CONTROL VALVE BODY REMOVAL/
except B5 (wiring harness-side). INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is there continuity?
7 VERIFY TROUBLESHOOTING OF DTC P0973 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–57
1890-1U-06H(05-02).fm 58 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0974 [AW6A-EL, AW6AX-EL]
id050211803500

DTC P0974 Shift solenoid A circuit malfunction (short to power/open circuit)

• Open or short circuit in shift solenoid A signal system (The solenoid remains on continuously for 100 ms or
more even if the TCM sends a solenoid off command).
Diagnostic support note:
DETECTION • This is continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit in wiring harness between shift solenoid A terminal A and TCM terminal B5
• Short to power in wiring harness between shift solenoid A terminal A and TCM terminal B5
POSSIBLE
• Shift solenoid A malfunction
CAUSE
• Damaged connector between shift solenoid A and TCM
• TCM malfunction
TCM

COUPLE COMPONENT
3
6 7
B5
5
4 A

SHIFT SOLENOID A

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID A WIRING

HARNESS-SIDE CONNECTOR

A
B5

05-02–58
1890-1U-06H(05-02).fm 59 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID A Yes Go to go to Step 8.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminal B5 (wiring harness-side)
and ground.
• Is resistance within 11—15 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID A FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the shift solenoid A connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminal B5 (wiring harness-side)
and shift solenoid A terminal A wiring harness-
side).
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO POWER next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminal B5 and all terminals (See 05-17-42 CONTROL VALVE BODY REMOVAL/
except B5 (wiring harness-side). INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P0974 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–59
1890-1U-06H(05-02).fm 60 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0976 [AW6A-EL, AW6AX-EL]
id050211803600

DTC P0976 Shift solenoid B circuit malfunction (short to ground)

• Short to ground in shift solenoid B signal system (The solenoid remains off continuously for 100 ms or
more even if the TCM sends a solenoid on command).
Diagnostic support note:
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Short to ground in wiring harness between shift solenoid B terminal A and TCM terminal B2
POSSIBLE • Shift solenoid B malfunction
CAUSE • Damaged connector between shift solenoid B and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6
B2
5
4 A

SHIFT SOLENOID B

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID B WIRING

HARNESS-SIDE CONNECTOR

B2

05-02–60
1890-1U-06H(05-02).fm 61 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID B Yes Go to go to Step 7.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminal B2 (wiring harness-side)
and ground.
• Is resistance within 11—15 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID B FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 7.
• Disconnect the shift solenoid B connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO GROUND next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminal B2 and all terminals (See 05-17-42 CONTROL VALVE BODY REMOVAL/
except B2 (wiring harness-side). INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is there continuity?
7 VERIFY TROUBLESHOOTING OF DTC P0976 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–61
1890-1U-06H(05-02).fm 62 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0977 [AW6A-EL, AW6AX-EL]
id050211803700

DTC P0977 Shift solenoid B circuit malfunction (short to power/open circuit)

• Open or short circuit in shift solenoid B signal system (The solenoid remains on continuously for 100 ms or
more even if the TCM sends a solenoid off command).
Diagnostic support note:
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit in wiring harness between shift solenoid B terminal A and TCM terminal B2
• Short to power in wiring harness between shift solenoid B terminal A and TCM terminal B2
POSSIBLE
• Shift solenoid B malfunction
CAUSE
• Damaged connector between shift solenoid A and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6 7
B2
5
4 A

SHIFT SOLENOID B

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID B WIRING

HARNESS-SIDE CONNECTOR

B2

05-02–62
1890-1U-06H(05-02).fm 63 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID B Yes Go to go to Step 8.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminal B2 (wiring harness-side)
and ground.
• Is resistance within 11—15 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID B FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the shift solenoid B connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminal B2 (wiring harness-side)
and shift solenoid A terminal A wiring harness-
side).
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO POWER next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminal B2 and all terminals (See 05-17-42 CONTROL VALVE BODY REMOVAL/
except B2 (wiring harness-side). INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P0977 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–63
1890-1U-06H(05-02).fm 64 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0978 [AW6A-EL, AW6AX-EL]
id050211803800

DTC P0978 Shift solenoid C range/performance (stuck)

• Feedback current corresponding to solenoid current command value is irregular when engine is running.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
POSSIBLE
• Shift solenoid C stuck
CAUSE
• Control valve stuck
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT [AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION [AW6A-EL, AW6AX-EL].)
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM TEST • Any ranges: Replace the ATX, then go the next step.
[AW6A-EL, AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P0978 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?

05-02–64
1890-1U-06H(05-02).fm 65 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie
DTC P0979 [AW6A-EL, AW6AX-EL]
id050211803900

DTC P0979 Shift solenoid C circuit malfunction (short to ground/open circuit)

• Open or short circuit in shift solenoid C signal system (The solenoid circuit current value input to the TCM is
continuously less than 23 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates. 05-02
• The DTC is stored in the TCM memory.
• Open circuit between shift solenoid C terminal B and TCM terminal B11
• Open circuit between shift solenoid C terminal A and TCM terminal B10
• Short to ground in wiring harness between shift solenoid C terminal B and TCM terminal B11
POSSIBLE
• Short to ground in wiring harness between shift solenoid C terminal A and TCM terminal B10
CAUSE
• Shift solenoid C malfunction
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6 7
B11 (+)
5
B

SHIFT SOLENOID C 4

A
5 3
6 7
B10 (-)

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID C WIRING
HARNESS-SIDE CONNECTOR

B A

B10 B11

05-02–65
1890-1U-06H(05-02).fm 66 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID C Yes Go to go to Step 8.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B11 and B10 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID C FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the shift solenoid C connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminals and line pressure control
solenoid terminals (wiring harness-side).
— Terminal B11 and terminal B
— Terminal B10 and terminal A
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO GROUND next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B11 and all terminals except B11/ INSTALLATION [AW6A-EL, AW6AX-EL].)
B10
— Terminal B10 and all terminals except B11/
B10
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P0979 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie

05-02–66
1890-1U-06H(05-02).fm 67 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0980 [AW6A-EL, AW6AX-EL]
id050211804000

DTC P0980 Shift solenoid C circuit malfunction (short to power)

• Short circuit in shift solenoid C signal system (The solenoid circuit current value input to the TCM is
continuously more than 1,333 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Short to power in wiring harness between shift solenoid C terminal B and TCM terminal B11
• Short to power in wiring harness between shift solenoid C terminal A and TCM terminal B10
POSSIBLE
• Shift solenoid C malfunction
CAUSE
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM 05-02

COUPLE COMPONENT
3
6
B11 (+)
5
B

SHIFT SOLENOID C 4

A
5 3
6
B10 (-)

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID C WIRING
HARNESS-SIDE CONNECTOR

B A

B10 B11

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?

05-02–67
1890-1U-06H(05-02).fm 68 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID C Yes Go to go to Step 7.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B11 and B10 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID C FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 7.
• Disconnect the shift solenoid C connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO POWER next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B11 and all terminals except B11/ INSTALLATION [AW6A-EL, AW6AX-EL].)
B10
— Terminal B10 and all terminals except B11/
B10
• Is there continuity?
7 VERIFY TROUBLESHOOTING OF DTC P0980 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie
DTC P0981 [AW6A-EL, AW6AX-EL]
id050211804100

DTC P0981 Shift solenoid D range/performance (stuck)

• Feedback current corresponding to solenoid current command value is irregular when engine is running.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
POSSIBLE
• Shift solenoid D stuck
CAUSE
• Control valve stuck
• TCM malfunction

05-02–68
1890-1U-06H(05-02).fm 69 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT [AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-11 AUTOMATIC TRANSAXLE 05-02
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION [AW6A-EL, AW6AX-EL].)
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM TEST • Any ranges: Replace the ATX, then go the next step.
[AW6A-EL, AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P0981 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–69
1890-1U-06H(05-02).fm 70 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0982 [AW6A-EL, AW6AX-EL]
id050211804200

DTC P0982 Shift solenoid D circuit malfunction (short to ground/open circuit)

• Open or short circuit in shift solenoid D signal system (The solenoid circuit current value input to the TCM is
continuously less than 23 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit between shift solenoid D terminal B and TCM terminal B17
• Open circuit between shift solenoid D terminal A and TCM terminal B18
• Short to ground in wiring harness between shift solenoid D terminal B and TCM terminal B17
POSSIBLE
• Short to ground in wiring harness between shift solenoid D terminal A and TCM terminal B18
CAUSE
• Shift solenoid D malfunction
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
6 7 3
B17 (+)
5
B

SHIFT SOLENOID D 4

A
5 6 7 3
B18 (-)

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID D WIRING
HARNESS-SIDE CONNECTOR

B A
B17 B18

05-02–70
1890-1U-06H(05-02).fm 71 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID D Yes Go to go to Step 8.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B17 and B18 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID D FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the shift solenoid D connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminals and line pressure control
solenoid terminals (wiring harness-side).
— Terminal B17 and terminal B
— Terminal B18 and terminal A
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO GROUND next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B17 and all terminals except B17/ INSTALLATION [AW6A-EL, AW6AX-EL].)
B18
— Terminal B18 and all terminals except B17/
B18
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P0982 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie

05-02–71
1890-1U-06H(05-02).fm 72 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0983 [AW6A-EL, AW6AX-EL]
id050211804300

DTC P0983 Shift solenoid D circuit malfunction (short to power)

• Short circuit in shift solenoid D signal system (The solenoid circuit current value input to the TCM is
continuously more than 1,333 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Short to power in wiring harness between shift solenoid D terminal B and TCM terminal B17
• Short to power in wiring harness between shift solenoid D terminal A and TCM terminal B18
POSSIBLE
• Shift solenoid D malfunction
CAUSE
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6
B17 (+)
5
B
4
SHIFT SOLENOID D

A
5 3
6
B18 (-)

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID D WIRING
HARNESS-SIDE CONNECTOR

B A
B17 B18

05-02–72
1890-1U-06H(05-02).fm 73 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID D Yes Go to go to Step 7.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B17 and B18 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID D FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 7.
• Disconnect the shift solenoid D connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO POWER next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B17 and all terminals except B17/ INSTALLATION [AW6A-EL, AW6AX-EL].)
B18
— Terminal B18 and all terminals except B17/
B18
• Is there continuity?
7 VERIFY TROUBLESHOOTING OF DTC P0983 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–73
1890-1U-06H(05-02).fm 74 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0984 [AW6A-EL, AW6AX-EL]
id050211804400

DTC P0984 Shift solenoid E range/performance (stuck)

• Feedback current corresponding to solenoid current command value is irregular when engine is running.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
POSSIBLE
• Shift solenoid E stuck
CAUSE
• Control valve stuck
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT [AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION [AW6A-EL, AW6AX-EL].)
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM TEST • Any ranges: Replace the ATX, then go the next step.
[AW6A-EL, AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P0984 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?

05-02–74
1890-1U-06H(05-02).fm 75 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie
DTC P0985 [AW6A-EL, AW6AX-EL]
id050211804500

DTC P0985 Shift solenoid E circuit malfunction (short to ground/open circuit)

• Open or short circuit in shift solenoid E signal system (The solenoid circuit current value input to the TCM is
continuously less than 23 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates. 05-02
• The DTC is stored in the TCM memory.
• Open circuit between shift solenoid E terminal B and TCM terminal B14
• Open circuit between shift solenoid E terminal A and TCM terminal B22
• Short to ground in wiring harness between shift solenoid E terminal B and TCM terminal B14
POSSIBLE
• Short to ground in wiring harness between shift solenoid E terminal A and TCM terminal B22
CAUSE
• Shift solenoid E malfunction
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
6 7 3
B14 (+)
5
B

SHIFT SOLENOID E 4

A
5 6 7 3
B22 (-)

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID E WIRING
HARNESS-SIDE CONNECTOR

B22
B A
B14

05-02–75
1890-1U-06H(05-02).fm 76 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID E Yes Go to go to Step 8.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B14 and B22 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID E FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the shift solenoid E connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminals and line pressure control
solenoid terminals (wiring harness-side).
— Terminal B14 and terminal B
— Terminal B22 and terminal A
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO GROUND next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B14 and all terminals except B14/ INSTALLATION [AW6A-EL, AW6AX-EL].)
B22
— Terminal B22 and all terminals except B14/
B22
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P0985 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie

05-02–76
1890-1U-06H(05-02).fm 77 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0986 [AW6A-EL, AW6AX-EL]
id050211804600

DTC P0986 Shift solenoid E circuit malfunction (short to power)

• Short circuit in shift solenoid E signal system (The solenoid circuit current value input to the TCM is
continuously more than 1,333 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Short to power in wiring harness between shift solenoid E terminal B and TCM terminal B14
• Short to power in wiring harness between shift solenoid E terminal A and TCM terminal B22
POSSIBLE
• Shift solenoid E malfunction
CAUSE
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM 05-02

COUPLE COMPONENT
3
6
B14 (+)
5
B
4
SHIFT SOLENOID E

A
5 3
6
B22 (-)

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID E WIRING
HARNESS-SIDE CONNECTOR

B22
B A
B14

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?

05-02–77
1890-1U-06H(05-02).fm 78 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID E Yes Go to go to Step 7.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B14 and B22 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID E FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 7.
• Disconnect the shift solenoid E connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO POWER next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B14 and all terminals except B14/ INSTALLATION [AW6A-EL, AW6AX-EL].)
B22
— Terminal B22 and all terminals except B14/
B22
• Is there continuity?
7 VERIFY TROUBLESHOOTING OF DTC P0986 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie
DTC P0997 [AW6A-EL, AW6AX-EL]
id050211804700

DTC P0997 Shift solenoid F range/performance (stuck)

• Feedback current corresponding to solenoid current command value is irregular when engine is running.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
POSSIBLE
• Shift solenoid F stuck
CAUSE
• Control valve stuck
• TCM malfunction

05-02–78
1890-1U-06H(05-02).fm 79 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT [AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-11 AUTOMATIC TRANSAXLE 05-02
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION [AW6A-EL, AW6AX-EL].)
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM TEST • Any ranges: Replace the ATX, then go the next step.
[AW6A-EL, AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P0997 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–79
1890-1U-06H(05-02).fm 80 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0998 [AW6A-EL, AW6AX-EL]
id050211804800

DTC P0998 Shift solenoid F circuit malfunction (short to ground/open circuit)

• Open or short circuit in shift solenoid F signal system (The solenoid circuit current value input to the TCM is
continuously less than 23 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit between shift solenoid F terminal B and TCM terminal B21
• Open circuit between shift solenoid F terminal A and TCM terminal B16
• Short to ground in wiring harness between shift solenoid F terminal B and TCM terminal B21
POSSIBLE
• Short to ground in wiring harness between shift solenoid F terminal A and TCM terminal B16
CAUSE
• Shift solenoid F malfunction
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6 7
B21 (+)
5
B
4
SHIFT SOLENOID F

A
5 6 7 3
B16 (-)

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID F WIRING
HARNESS-SIDE CONNECTOR

B21
B A
B16

05-02–80
1890-1U-06H(05-02).fm 81 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID F Yes Go to go to Step 8.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B21 and B16 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID F FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the shift solenoid F connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminals and line pressure control
solenoid terminals (wiring harness-side).
— Terminal B21 and terminal B
— Terminal B16 and terminal A
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO GROUND next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B21 and all terminals except B21/ INSTALLATION [AW6A-EL, AW6AX-EL].)
B16
— Terminal B16 and all terminals except B21/
B16
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P0998 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie

05-02–81
1890-1U-06H(05-02).fm 82 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P0999 [AW6A-EL, AW6AX-EL]
id050211804900

DTC P0999 Shift solenoid F circuit malfunction (short to power)

• Short circuit in shift solenoid F signal system (The solenoid circuit current value input to the TCM is
continuously more than 1,333 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Short to power in wiring harness between shift solenoid F terminal B and TCM terminal B21
• Short to power in wiring harness between shift solenoid F terminal A and TCM terminal B16
POSSIBLE
• Shift solenoid F malfunction
CAUSE
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6
B21 (+)
5
B

SHIFT SOLENOID F 4

A
5 3
6
B16 (-)

COUPLE COMPONENT CONNECTOR

SHIFT SOLENOID F WIRING
HARNESS-SIDE CONNECTOR

B21
B A
B16

05-02–82
1890-1U-06H(05-02).fm 83 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID F Yes Go to go to Step 7.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B21 and B16 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID F FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 7.
• Disconnect the shift solenoid F connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO POWER next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B21 and all terminals except B21/ INSTALLATION [AW6A-EL, AW6AX-EL].)
B16
— Terminal B16 and all terminals except B21/
B16
• Is there continuity?
7 VERIFY TROUBLESHOOTING OF DTC P0999 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–83
1890-1U-06H(05-02).fm 84 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P1700 [AW6A-EL, AW6AX-EL]
id050211805000

DTC P1700 Valve control solenoid circuit malfunction at R range (valve stuck)
• When all of the following conditions are met while driving in R position and the counter drive gear (output}
speed is 500 rpm or less:
— The difference between the engine and turbine shaft speeds is less than 150 rpm
— The turbine shaft speed is more than the estimated turbine speed value, as derived from the counter
drive gear (output) speed, plus 200 rpm.
DETECTION
Diagnostic support note:
CONDITION
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Shift solenoid A stuck
• Shift solenoid B stuck
• Shift solenoid E stuck
POSSIBLE
• C3 clutch slipping
CAUSE
• B2 brake slipping
• Control valve stuck
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 6.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 6.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
4 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go the Step 6.
(See 05-17-3 MECHANICAL SYSTEM TEST (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
[AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
5 INSPECT SOLENOID VALVE Yes Go to the next step.
• Inspect the solenoid valve. No Replace the control valve body, then go to the next step.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
6 VERIFY TROUBLESHOOTING OF DTC P1700 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in R position.
• Is the same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–84
1890-1U-06H(05-02).fm 85 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P1719 [AW6A-EL, AW6AX-EL]
id050211816700

DTC P1719 Engine torque signal error (inaccurate signal)

• With all of the following conditions met, if the engine torque signal from the PCM, which is transmitted using
the CAN communication, is not normal and the condition has continued for 0.02 s or more.
— Engine speed: 500 rpm or more
— Accelerator pedal opening angle: 2 % or more
Diagnostic support note:
DETECTION
CONDITION • This is a continuous monitor (CCM).
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The MIL not illuminates.
• The AT warning light not illuminates.
• The DTC is stored in the TCM memory.
POSSIBLE • PCM malfunction
CAUSE • TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION 05-02
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY DTC Yes Go to the applicable DTC inspection.
• Turn the ignition switch to the LOCK position, (See 01-02-12 DTC TABLE [MZI-3.5].)
then to the ON position. No Go to the next step.
• Verify the DTC in the PCM memory.
• Are any DTCs stored?
4 VERIFY TROUBLESHOOTING OF DTC P1719 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle under the following
conditions:
— Drive in the D range
— Engine speed: 500 rpm or more
— Accelerator pedal opening angle: 2 % or
more
• Is the same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–85
1890-1U-06H(05-02).fm 86 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P1919 [AW6A-EL, AW6AX-EL]
id050211816800

DTC P1919 Engine coolant temperature signal error

• If the engine coolant temperature signal from the PCM, which is transmitted using the CAN communication,
is invalid and the condition has continued for 500 ms or more.
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The MIL not illuminates.
• The AT warning light not illuminates.
• The DTC is stored in the TCM memory.
• CHT sensor malfunction
POSSIBLE
• PCM malfunction
CAUSE
• TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY DTC Yes Go to the applicable DTC inspection.
• Turn the ignition switch to the LOCK position, (See 01-02-12 DTC TABLE [MZI-3.5].)
then to the ON position. No Go to the next step.
• Verify the DTC in the PCM memory.
• Are any DTCs stored?
4 VERIFY TROUBLESHOOTING OF DTC P1919 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range for 500 ms or
more.
• Is the same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–86
1890-1U-06H(05-02).fm 87 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P2544 [AW6A-EL, AW6AX-EL]
id050211816600

DTC P2544 Engine torque signal error (invalid signal)

• If the engine torque signal or engine torque-loss signal from the PCM, which is transmitted using the CAN
communication, is invalid and the condition has continued for 500 ms or more
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
POSSIBLE • PCM malfunction
CAUSE • TCM malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED 05-02
No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY DTC Yes Go to the applicable DTC inspection.
• Turn the ignition switch to the LOCK position, (See 01-02-12 DTC TABLE [MZI-3.5].)
then to the ON position. No Go to the next step.
• Verify the DTC in the PCM memory.
• Are any DTCs stored?
4 VERIFY TROUBLESHOOTING OF DTC P2544 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range for 500 ms or
more.
• Is the same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–87
1890-1U-06H(05-02).fm 88 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P2757 [AW6A-EL, AW6AX-EL]
id050211805100

DTC P2757 Torque converter clutch (TCC) stuck off

• When all conditions below are satisfied.
— ATF temperature 20 °C {68 °F} or more
— Driving in 4GR—6GR at D range
— Engine running
— Torque converter clutch (TCC) operating
— Difference between engine speed and counter drive gear (output) revolution speed (VSS) 100 rpm or
DETECTION more
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
• TCC control solenoid stuck
POSSIBLE
• Line pressure low
CAUSE
• Control valve stuck.
• Torque converter malfunction
• TCM malfunction

05-02–88
1890-1U-06H(05-02).fm 89 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is milky or reddish brown, replace ATF, then
• Inspect the ATF condition. go to Step 7.
— Clear red: Normal (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT [AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-11 AUTOMATIC TRANSAXLE 05-02
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION [AW6A-EL, AW6AX-EL].)
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 7.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 6.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT TCC CONTROL SOLENOID Yes Replace the Torque converter, then go to the next step.
• Inspect the TCC control solenoid. (See 05-17-50 TORQUE CONVERTER REMOVAL/
(See 05-17-21 SOLENOID VALVE INSTALLATION [AW6A-EL, AW6AX-EL].)
INSPECTION [AW6A-EL, AW6AX-EL].) No Replace the control valve body, then go to the next step.
• Is it normal? (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
7 VERIFY TROUBLESHOOTING OF DTC P2757 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Start the engine.
• Warm up engine and ATX.
• Drive the vehicle under the following conditions
for 2 s or more.
— ATF temperature (TFT PID): 20 °C {68 °F}
or more
— Drive in the D range, 4GR—6GR (TCC
operation)
• Are any DTCs present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–89
1890-1U-06H(05-02).fm 90 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P2758 [AW6A-EL, AW6AX-EL]
id050211805200

DTC P2758 Torque converter clutch (TCC) stuck on

• All of the following conditions are satisfied under each of the following accelerator conditions.
— ATF temperature 20 °C {68 °F} or more
— Driving in D range
— Engine running
— Engine speed within 1,000—3,000rpm
— Torque converter clutch (TCC) no operating
DETECTION — Difference between engine speed and turbine revolution speed less than 30 rpm
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL does not illuminate if PCM detects the above malfunction conditions during first the drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is not available.
• The AT warning light illuminates.
• The DTC is stored in the PCM memory.
• ATF level low
• Deteriorated ATF
• TCC control solenoid stuck
POSSIBLE
• Line pressure low
CAUSE
• Control valve stuck
• Torque converter malfunction
• TCM malfunction

05-02–90
1890-1U-06H(05-02).fm 91 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is milky or reddish brown, replace ATF, then
• Inspect the ATF condition. go to Step 7.
— Clear red: Normal (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT [AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-11 AUTOMATIC TRANSAXLE 05-02
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION [AW6A-EL, AW6AX-EL].)
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 7.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM TEST Step 6.
[AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT TCC CONTROL SOLENOID Yes Replace the Torque converter, then go to the next step.
• Inspect the TCC control solenoid. (See 05-17-50 TORQUE CONVERTER REMOVAL/
(See 05-17-21 SOLENOID VALVE INSTALLATION [AW6A-EL, AW6AX-EL].)
INSPECTION [AW6A-EL, AW6AX-EL].) No Replace the control valve body, then go to the next step.
• Is it normal? (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
7 VERIFY TROUBLESHOOTING OF DTC P2758 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Start the engine.
• Warm up engine and ATX.
• Drive the vehicle under the following conditions
for 2 s or more.
— ATF temperature (TFT PID):20 °C {68 °F} or
more
— Engine speed: less than 3,000 rpm
— Drive in the D range, 4GR—6GR (TCC no
operation)
• Are any DTCs present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–91
1890-1U-06H(05-02).fm 92 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P2762 [AW6A-EL, AW6AX-EL]
id050211805300

DTC P2762 TCC control solenoid range/performance (stuck)

• Feedback current corresponding to solenoid current command value is irregular when engine is running.
Diagnostic support note:
• This is a continuous monitor (CCM).
DETECTION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
CONDITION • A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
POSSIBLE
• TCC control solenoid stuck
CAUSE
• Control valve stuck
• TCM malfunction

05-02–92
1890-1U-06H(05-02).fm 93 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT [AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-11 AUTOMATIC TRANSAXLE 05-02
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION [AW6A-EL, AW6AX-EL].)
(See 05-17-11 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM TEST • Any ranges: Replace the ATX, then go the next step.
[AW6A-EL, AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION [AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT TCC CONTROL SOLENOID Yes Go to the next step.
• Inspect the TCC control solenoid. No Replace the control valve body.
(See 05-17-21 SOLENOID VALVE (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P2762 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–93
1890-1U-06H(05-02).fm 94 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P2763 [AW6A-EL, AW6AX-EL]
id050211805400

DTC P2763 TCC control solenoid circuit malfunction (short to power)

• Short circuit in TCC control solenoid signal system (while TCM monitors solenoid output voltage, the
voltage that differs from the signal output by CPU in TCM is detected).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Short to power in wiring harness between TCC control solenoid terminal B and TCM terminal B9
• Short to power in wiring harness between TCC control solenoid terminal A and TCM terminal B4
POSSIBLE
• TCC control solenoid malfunction
CAUSE
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT
3
6
B9 (+)
5
B
TCC CONTROL 4
SOLENOID

A
5 3
6
B4 (-)

COUPLE COMPONENT CONNECTOR

TCC CONTROL SOLENOID
WIRING HARNESS-SIDE CONNECTOR

B A

B9

B4

05-02–94
1890-1U-06H(05-02).fm 95 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF TCC CONTROL Yes Go to go to Step 7.
SOLENOID CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B9 and B4 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL TCC CONTROL Yes Go to the next step.
SOLENOID FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Disconnect the TCC control solenoid
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO POWER next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B9 and all terminals except B9/B4 INSTALLATION [AW6A-EL, AW6AX-EL].)
— Terminal B4 and all terminals except B9/B4
• Is there continuity?
7 VERIFY TROUBLESHOOTING OF DTC P2763 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–95
1890-1U-06H(05-02).fm 96 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

DTC P2764 [AW6A-EL, AW6AX-EL]
id050211805500

DTC P2764 TCC control solenoid circuit malfunction (short to ground/open circuit)
• Open or short circuit in TCC control solenoid signal system (while TCM monitors solenoid output voltage,
the voltage that differs from the signal output by CPU in TCM is detected).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit between TCC control solenoid terminal B and TCM terminal B9
• Open circuit between TCC control solenoid terminal A and TCM terminal B4
• Short to ground in wiring harness between TCC control solenoid terminal B and TCM terminal B9
POSSIBLE
• Short to ground in wiring harness between TCC control solenoid terminal A and TCM terminal B4
CAUSE
• TCC control solenoid malfunction
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction

TCM

COUPLE COMPONENT

6 7 3
B9 (+)
5
B
TCC CONTROL 4
SOLENOID

A
5 6 7 3
B4 (-)

COUPLE COMPONENT CONNECTOR

TCC CONTROL SOLENOID
WIRING HARNESS-SIDE CONNECTOR

B A

B9

B4

05-02–96
1890-1U-06H(05-02).fm 97 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion). 05-02
• Are terminals normal?
4 INSPECT RESISTANCE OF TCC CONTROL Yes Go to go to Step 8.
SOLENOID CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B9 and B4 (wiring
harness-side).
• Is resistance within 5.0—5.6 ohms?
(See 05-17-21 SOLENOID VALVE
INSPECTION [AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL TCC CONTROL Yes Go to the next step.
SOLENOID FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the TCC control solenoid
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
6 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the couple component, then go to Step 8.
• Inspect for continuity between couple
component terminals and line pressure control
solenoid terminals (wiring harness-side).
— Terminal B9 and terminal B
— Terminal B4 and terminal A
• Is there continuity?
7 INSPECT TERMINAL COUPLE COMPONENT Yes Repair or replace the couple component, then go to the
CIRCUIT FOR SHORT TO GROUND next step.
• Inspect for continuity between couple No Replace the control valve body, then go to the next step.
component terminals (wiring harness-side). (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Terminal B9 and all terminals except B9/B4 INSTALLATION [AW6A-EL, AW6AX-EL].)
— Terminal B4 and all terminals except B9/B4
• Is there continuity?
8 VERIFY TROUBLESHOOTING OF DTC P2764 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-
• Make sure to reconnect all the disconnected EL, AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?

End Of Sie

05-02–97
1890-1U-06H(05-02).fm 98 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

PID/DATA MONITOR INSPECTION [AW6A-EL, AW6AX-EL]
id050211805600
1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “TCM”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “TCM”.
3. Select “DataLogger”.
ac9uuw00002099
3. Select the PID from the PID table.
4. Verify the PID data according to the directions on
the M-MDS screen.
Note
• Perform part inspection for the output device after TCM inspection.
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the TCM.
Therefore, if a monitored value of an output device is out of specification, it is necessary to inspect the
monitored value of the input device related to the output device control. Since an output device
malfunction is not directly indicated as a malfunction of the monitored value for the output device, it is
necessary to inspect the output device individually using the simulation function.
PID/DATA MONITOR AND RECORD function table
Monitor item Unit/ TCM
Condition/Specification Action
(Definition) Condition terminal
Inspect the brake switch.
BOO TCM • Brake pedal depressed: On
On/Off (See 04-11-7 BRAKE SWITCH –
(Brake switch) • Other: Off
INSPECTION.)
Check DTC.
DTCCNT – Indicates number of DTC (See 05-02-5 DTC TABLE [AW6A-EL, –
AW6AX-EL].)
Inspect the selector lever component.
DWN SW • Down shift at M range: On
On/Off (See 05-18-7 SELECTOR LEVER A4
(Down switch) • Other: Off
COMPONENT INSPECTION.)
ECT TCM Inspect the PCM.
(Engine (See 01-40-5 PCM INSPECTION [MZI-
°C Indicates ECT –
coolant 3.5].)
temperature)
FDPDTC Inspect the TCM.
Indicates code of FREEZE FRAME
(FREEZE – (See 05-17-22 TCM INSPECTION –
DATA
FRAME DATA) [AW6A-EL, AW6AX-EL].)
• 1GR: 4.148 Inspect following PIDs: THOP, TSS, VSS
• 2GR: 2.370
GEAR_RA • 3GR: 1.555
– –
(Gear ratio) • 4GR: 1.154
• 5GR: 0.859
• 6GR: 0.685
• 1GR: 1st Inspect following PIDs: THOP, TSS, VSS
GEAR_SEL • 2GR: 2nd
(Calculated 1st/2nd/3rd/ • 3GR: 3rd
–
gear range in 4th/5th/6th • 4GR: 4th
TCM) • 5GR: 5th
• 6GR: 6th
LPS Inspect the pressure control solenoid.
(Pressure (See 05-17-21 SOLENOID VALVE
A 100—1,000 mA B1, B3
control INSPECTION [AW6A-EL, AW6AX-EL].)
solenoid)
MNL SW Inspect the selector lever component.
• M range: On
(M range On/Off (See 05-18-7 SELECTOR LEVER A7
• Other: Off
switch) COMPONENT INSPECTION.)
Inspect the VSS.
OSS
• Ignition switch ON:0 RPM (See 05-17-18 VEHICLE SPEED
(Output shaft RPM B19, B20
• Indicates output shaft speed SENSOR (VSS) INSPECTION [AW6A-
speed)
EL, AW6AX-EL].)

05-02–98
1890-1U-06H(05-02).fm 99 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Monitor item Unit/ TCM
Condition/Specification Action
(Definition) Condition terminal
Inspect the TR switch.
PNP_TCM Drive/ • P, N position: Neutral
(See 05-17-22 TCM INSPECTION –
(Park/Neutral) Neutral • D, M range or R position: Drive
[AW6A-EL, AW6AX-EL].)
RPM TCM Inspect the PCM.
• Ignition switch ON:0 RPM
(Engine RPM (See 01-40-5 PCM INSPECTION [MZI- –
• Idle:700—800 RPM
speed) 3.5].)
• P, R, N position or D/M range (5GR, Inspect the shift solenoid C.
SSC
6GR): solenoid on (See 05-17-21 SOLENOID VALVE
(Shift solenoid A B10, B11
• Other: solenoid off INSPECTION [AW6A-EL, AW6AX-EL].)
C)
— 100—1,000 mA
• P, R, N position or D/M range (1GR, Inspect the shift solenoid D.
SSD
2GR, 3GR): solenoid on (See 05-17-21 SOLENOID VALVE
(Shift solenoid A B17, B18
• Other: solenoid off INSPECTION [AW6A-EL, AW6AX-EL].)
D)
— 100—1,000 mA
• R position (more than 11 km/h {4 Inspect the shift solenoid E.
SSE mph}) or D/M range (1GR, 2GR, (See 05-17-21 SOLENOID VALVE
(Shift solenoid A 4GR, 6GR): solenoid on INSPECTION [AW6A-EL, AW6AX-EL].) B14, B22 05-02
E) • Other: solenoid off
— 100—1,000 mA
• P, R, N position or D/M range (1GR, Inspect the shift solenoid F.
SSF
3GR, 4GR, 5GR): solenoid on (See 05-17-21 SOLENOID VALVE
(Shift solenoid A B16, B21
• Other: solenoid off INSPECTION [AW6A-EL, AW6AX-EL].)
F)
— 100—1,000 mA
TCCC • TCC on: solenoid on Inspect the TCC control solenoid.
(TCC control A • Other: solenoid off (See 05-17-21 SOLENOID VALVE B4, B9
solenoid) — 200—1,000 mA INSPECTION [AW6A-EL, AW6AX-EL].)
Inspect the TFT sensor.
TFT
(See 05-17-13 TRANSAXLE FLUID
(ATF °C Indicates ATF temperature B7, B8
TEMPERATURE (TFT) SENSOR
temperature)
INSPECTION [AW6A-EL, AW6AX-EL].)
• ATF temperature 10 °C {50 Inspect the TFT sensor.
TFTV °F}:4.78—4.81 V (See 05-17-13 TRANSAXLE FLUID
(ATF • ATF temperature 25 °C {77 TEMPERATURE (TFT) SENSOR
V B7, B8
temperature °F}:4.61—4.65 V INSPECTION [AW6A-EL, AW6AX-EL].)
signal voltage) • ATF temperature 110 °C {230
°F}:2.30—2.45 V
THOP Inspect the PCM.
• CTP: 0%
(Throttle % (See 01-40-5 PCM INSPECTION [MZI- –
• WOT: 100%
position) 3.5].)
• R position: R Inspect the TR switch.
TR • N position: N (See 05-17-22 TCM INSPECTION
R/N/D/P –
(TR switch) • D range: D [AW6A-EL, AW6AX-EL].)
• P position: P
TRD Inspect the TR switch.
• D range: On
(TR switch [D On/Off (See 05-17-22 TCM INSPECTION –
• Other ranges and all positions: Off
range]) [AW6A-EL, AW6AX-EL].)
TRR Inspect the TR switch.
• R position: On
(TR switch [R On/Off (See 05-17-22 TCM INSPECTION –
• Other positions and all ranges: Off
position]) [AW6A-EL, AW6AX-EL].)
Inspect the input/turbine speed sensor.
TSS
• Ignition switch ON:0 RPM (See 05-17-16 INPUT/TURBINE SPEED
(Input/turbine RPM –
• Idle:700—800 RPM SENSOR INSPECTION [AW6A-EL,
speed sensor)
AW6AX-EL].)
Inspect the selector lever component.
UP SW • Up shift at M range: On
On/Off (See 05-18-7 SELECTOR LEVER A3
(Up switch) • Other: Off
COMPONENT INSPECTION.)
Inspect the VSS.
VSS
(See 05-17-18 VEHICLE SPEED
(Vehicle KPH, MPH Indicates vehicle speed –
SENSOR (VSS) INSPECTION [AW6A-
speed)
EL, AW6AX-EL].)

– : N/A

05-02–99
1890-1U-06H(05-02).fm 100 ページ ２００６年１２月１９日　火曜日　午前１１時４９分

ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]

Simulation Function Procedure
1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Modules”.
4. Select “TCM”.
• When using the PDS (Pocket PC) DLC-2
1. Select “Module Tests”.
2. Select “TCM”.
3. Select “DataLogger”.
ac9uuw00002099
3. Select the simulation items from the PID table.
4. Perform the simulation function, inspect the
operations for each parts.
• If there is no operation sound from the solenoid after the simulation function inspection is performed, it is
possible that there is an open or short circuit in the wiring harness, or solenoid, or sticking and operation
malfunction.
Simulation item table
X: Available
Simulation Operation
Applicable component Unit/Condition TCM terminal
item IG ON Idle
Pressure control solenoid control signal
LPS A X X B1, B3
in TCM
SSA Shift solenoid A On/Off X X B5
SSB Shift solenoid B On/Off X X B2
SSC Shift solenoid C A X X B10, B11
SSD Shift solenoid D A X X B17, B18
SSE Shift solenoid E A X X B14, B22
SSF Shift solenoid F A X X B16, B21

End Of Sie

05-02–100
1890-1U-06H(05-03).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

05-03 SYMPTOM TROUBLESHOOTING [AW6A-EL,
AW6AX-EL]
AUTOMATIC TRANSAXLE CONTROL NO.16 JUDDER UPON TORQUE
SYSTEM WIRING DIAGRAM CONVERTER CLUTCH (TCC)
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–2 OPERATION
FOREWORD [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–22
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–3 NO.17 EXCESSIVE SHIFT SHOCK FROM
BASIC INSPECTION N TO D OR N TO R POSITION/RANGE
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–4 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–22
SYMPTOM TROUBLESHOOTING ITEM Initial Learning. . . . . . . . . . . . . . . . . . . . 05-03–23
TABLE [AW6A-EL, AW6AX-EL] . . . . . . 05-03–4 NO.18 EXCESSIVE SHIFT SHOCK IS
QUICK DIAGNOSIS CHART GIVEN WHEN UPSHIFTING AND
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–7 DOWNSHIFTING
NO.1 VEHICLE DOES NOT MOVE IN [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–24
D RANGE, OR IN R POSITION NO.19 EXCESSIVE SHIFT SHOCK ON
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–11 TORQUE CONVERTER CLUTCH (TCC) 05-03
NO.2 VEHICLE MOVES IN N POSITION [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–24
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–12 NO.20 NOISE OCCURS AT IDLE
NO.3 VEHICLE MOVES IN P POSITION, WHEN VEHICLE IS STOPPED IN ALL
OR PARKING GEAR DOES NOT POSITIONS/RANGES
DISENGAGE WHEN P IS DISENGAGED [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–24
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–12 NO.21 NOISE OCCURS AT IDLE WHEN
NO.4 EXCESSIVE CREEP VEHICLE IS STOPPED IN D RANGE,
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–12 OR IN R POSITION
NO.5 NO CREEP AT ALL [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–25
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–13 NO.22 NO ENGINE BRAKING IN 1GR
NO.6 LOW MAXIMUM SPEED AND POSITION OF M RANGE
POOR ACCELERATION [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–25
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–14 NO.23 TRANSAXLE OVERHEATS
NO.7 NO SHIFTING [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–26
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–15 NO.24 ENGINE STALLS WHEN
NO.8 DOES NOT SHIFT TO 6GR SHIFTED TO D RANGE, OR IN
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–16 R POSITION
NO.9 ABNORMAL SHIFTING [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–27
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–18 NO.25 ENGINE STALLS WHEN
NO.10 FREQUENT SHIFTING DRIVING AT SLOW SPEED OR
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–18 STOPPING
NO.11 SHIFT POINT IS HIGH OR LOW [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–27
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–19 NO.26 STARTER DOES NOT WORK
NO.12 TORQUE CONVERTER CLUTCH [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–28
(TCC) NON-OPERATION NO.27 GEAR POSITION INDICATOR
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–19 LIGHT DOES NOT ILLUMINATE IN
NO.13 NO KICKDOWN D OR M RANGE
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–20 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–29
NO.14 ENGINE FLARES UP OR SLIPS NO.28 GEAR POSITION INDICATOR
WHEN UPSHIFTING OR LIGHT ILLUMINATE IN P, R OR
DOWNSHIFTING N RANGE
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–20 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–30
NO.15 ENGINE FLARES UP OR SLIPS NO.29 DOES NOT UPSHIFT IN
WHEN ACCELERATING VEHICLE M RANGE
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-03–21 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–31
NO.30 DOES NOT DOWNSHIFT IN
M RANGE
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-03–31

End of Toc
WM: AUTOMATIC TRANSAXLE

05-03–1
1890-1U-06H(05-03).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

AUTOMATIC TRANSAXLE CONTROL SYSTEM WIRING DIAGRAM [AW6A-EL, AW6AX-EL]
id050310800100

SHIFT SOLENOID A
TR SWITCH
(INTEGRATED IN TCM) B5

SHIFT SOLENOID B

B2

VEHICLE SPEED SENSOR

B19
TCC CONTROL
B20
SOLENOID
INPUT/TURBINE SPEED
B9
SENSOR
B12 B4

B13
LINE PRESSURE
CONTROL SOLENOID
B8 B3

TFT SENSOR B1

B7

SHIFT SOLENOID F
UP SWITCH B21
A3
B16
DOWN SWITCH
A4
M RANGE SWITCH
A7
TCM SHIFT SOLENOID C
B11
OTHER MODULE
CAN-H B10
A14
CAN
CAN-L
A6 SHIFT SOLENOID D
B17
OTHER MODULE
B18

SHIFT SOLENOID E
B14

B22
IG1

A11
B+ STARTER LOCK
A5 PCM

A1

GND BACK-UP LIGHT RELAY

A9 A13

ac9uuw00002244
End Of Sie

05-03–2
1890-1U-06H(05-03).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

FOREWORD [AW6A-EL, AW6AX-EL]
id050310800200
• When the customer reports a vehicle malfunction, inspect the malfunction indicator lamp (MIL) indication, AT
warning indicator light flash, and diagnostic trouble code (DTC), then diagnose the malfunction according to
following flowchart.
— If a DTC exists, diagnose the applicable DTC inspection. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-
EL].)
— If a DTC does not exist, the MIL does not illuminate and the AT warning indicator light illuminate, diagnose
the applicable symptom troubleshooting. (See 05-03-4 SYMPTOM TROUBLESHOOTING ITEM TABLE
[AW6A-EL, AW6AX-EL].)

CUSTOMER ARRIVES

05-03
WARNING LIGHT* NO WARNING LIGHT*
ON/FLASHING WITH SYMPTOM

CHECK FOR CHECK DTC

PRIORITIZED DTC IGNITION ON TEST, IDLING
TEST
DTC

WITHOUT DTC

DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC) DIAGNOSE BY SYMPTOM
DTC TABLE (SYMPTOM TROUBLESHOOTING)
DTC 1. DIAGNOSTIC INDEX
TROUBLESHOOTING 2. QUICK DIAGNOSIS CHART
FLOW 3. SYMPTOM
TROUBLESHOOTING

ac9uuw00002103

*: Malfunction Indicator Lamp (MIL), AT warning light.

End Of Sie

05-03–3
1890-1U-06H(05-03).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

BASIC INSPECTION [AW6A-EL, AW6AX-EL]
id050310800300

STEP INSPECTION ACTION

1 • Measure the battery voltage. Yes Go to the next step.
• Is the battery voltage 10.0—14.0 V? No Replace or recharge the battery.
(See 01-17-4 BATTERY RECHARGING [MZI-3.5].)
2 • Inspect the TCM related harnesses, Yes Go to the next step.
connectors and fuses. No Repair or replace any malfunctioning parts according to the
• Are they normal? inspection result.
3 • Warm up the engine to normal operating Yes Record Freeze Frame Data and perform appropriate DTC
temperature. troubleshooting procedures.
• Retrieve DTC using the M-MDS. No Go to the next step.
• Is there any DTC present?
4 • Perform the road test. Yes Go to the next step.
• Is the ATX operating normally? No Repair or replace any malfunctioning parts according to the
inspection result.
5 • Perform the time lag test. Yes Go to the next step.
• Is the ATX operating normally? No Repair or replace any malfunctioning parts according to the
inspection result.
6 • Perform the stall test. Yes Go to the next step.
• Is the stall speed within the specified? No Repair or replace any malfunctioning parts according to the
inspection result.
7 • Perform the line pressure test. Yes Perform the symptom troubleshooting and follow the
• Is the line pressure within the specified? procedures.
No Repair or replace any malfunctioning parts according to the
inspection result.
8 • Inspect following part or signal related PIDs Yes Perform the symptom troubleshooting and follow the
using the M-MDS. procedures.
— APP sensor No Repair or replace any malfunctioning parts according to the
— TSS inspection result.
— VSS
— TFT sensor
— TR switch
— M range switch
— Up switch
— Down switch
— Brake switch
— Engine speed
• Are they normal?

End Of Sie
SYMPTOM TROUBLESHOOTING ITEM TABLE [AW6A-EL, AW6AX-EL]
id050310800400
• Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area.
No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
1 • Vehicle does not move in D range, • Vehicle does not move when accelerator (See 05-03-11 NO.1 VEHICLE
or in R position pedal is depressed. DOES NOT MOVE IN D
RANGE, OR IN R POSITION
[AW6A-EL, AW6AX-EL].)
2 • Vehicle moves in N position • Vehicle creeps in N position. (See 05-03-12 NO.2 VEHICLE
• Vehicle creeps if brake pedal is not MOVES IN N POSITION
depressed in N position. [AW6A-EL, AW6AX-EL].)
3 • Vehicle moves in P position, or • Vehicle rolls when on a downward slope (See 05-03-12 NO.3 VEHICLE
parking gear does not disengage and tires do not lock in P position. MOVES IN P POSITION, OR
when P position is disengaged • Tires locked when P position is PARKING GEAR DOES NOT
disengaged, vehicle does not move in D DISENGAGE WHEN P IS
range, and R position when accelerator DISENGAGED [AW6A-EL,
pedal is depressed, and engine remains AW6AX-EL].)
in stalled condition.
4 • Excessive creep • Vehicle accelerates in D range, and R (See 05-03-12 NO.4
position when accelerator pedal is not EXCESSIVE CREEP [AW6A-
depressed. EL, AW6AX-EL].)
5 • No creep at all • Vehicle does not move in D range, or R (See 05-03-13 NO.5 NO
position when idling on flat paved road. CREEP AT ALL [AW6A-EL,
AW6AX-EL].)

05-03–4
1890-1U-06H(05-03).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
6 • Low maximum speed and poor • Vehicle acceleration is poor at start. (See 05-03-14 NO.6 LOW
acceleration • Delayed acceleration when accelerator MAXIMUM SPEED AND
pedal is depressed while driving. POOR ACCELERATION
[AW6A-EL, AW6AX-EL].)
7 • No shifting • Single shift range only. (See 05-03-15 NO.7 NO
• Sometimes shifts correctly. SHIFTING [AW6A-EL, AW6AX-
EL].)
8 • Does not shift to 6GR • Vehicle does not upshift from 5GR to (See 05-03-16 NO.8 DOES
6GR even though vehicle speed NOT SHIFT TO 6GR [AW6A-
increased. EL, AW6AX-EL].)
• Vehicle does not shift to 6GR even
though accelerator pedal is released in
D range at 80 km/h {50 mph}.
9 • Abnormal shifting • Shifts incorrectly (incorrect shift pattern). (See 05-03-18 NO.9
ABNORMAL SHIFTING
[AW6A-EL, AW6AX-EL].)
10 • Frequent shifting • Downshifting occurs suddenly even (See 05-03-18 NO.10
when accelerator pedal is depressed FREQUENT SHIFTING 05-03
slightly in D range. [AW6A-EL, AW6AX-EL].)
11 • Shift point is high or low • Shift point considerably different from (See 05-03-19 NO.11 SHIFT
automatic shift diagram. POINT IS HIGH OR LOW
• Shift delays when accelerating. [AW6A-EL, AW6AX-EL].)
• Shift occurs suddenly when accelerating
and engine speed does not increase.
12 • Torque converter clutch (TCC) • TCC does not operate when vehicle (See 05-03-19 NO.12
non-operation reaches TCC operation range. TORQUE CONVERTER
CLUTCH (TCC) NON-
OPERATION [AW6A-EL,
AW6AX-EL].)
13 • No kickdown • Does not downshift when accelerator (See 05-03-20 NO.13 NO
pedal is fully depressed within kickdown KICKDOWN [AW6A-EL,
range. AW6AX-EL].)
14 • Engine flares up or slips when • When accelerator pedal is depressed, (See 05-03-20 NO.14 ENGINE
upshifting or downshifting engine speed increases normally but FLARES UP OR SLIPS WHEN
vehicle speed increases slowly. UPSHIFTING OR
• When accelerator pedal is depressed DOWNSHIFTING [AW6A-EL,
while driving, engine speed increases AW6AX-EL].)
but vehicle speed does not increase.
15 • Engine flares up or slips when • Engine flares up when accelerator pedal (See 05-03-21 NO.15 ENGINE
accelerating vehicle is depressed for upshifting. FLARES UP OR SLIPS WHEN
• Engine flares up suddenly when ACCELERATING VEHICLE
accelerator pedal is depressed for [AW6A-EL, AW6AX-EL].)
downshifting.
16 • Judder upon torque converter • Vehicle jolts when TCC is engaged. (See 05-03-22 NO.16
clutch (TCC) operation JUDDER UPON TORQUE
CONVERTER CLUTCH (TCC)
OPERATION [AW6A-EL,
AW6AX-EL].)
17 • Excessive shift shock from N to D • Strong shock is felt when shifting from N (See 05-03-22 NO.17
or N to R position/range to D or N to R position/range at idle. EXCESSIVE SHIFT SHOCK
FROM N TO D OR N TO R
POSITION/RANGE [AW6A-EL,
AW6AX-EL].)
18 • Excessive shift shock is given • Excessive shift shock is felt when (See 05-03-24 NO.18
when upshifting and downshifting depressing accelerator pedal to EXCESSIVE SHIFT SHOCK IS
accelerate at upshifting. GIVEN WHEN UPSHIFTING
• During cruising, excessive shift shock is AND DOWNSHIFTING [AW6A-
felt when depressing accelerator pedal EL, AW6AX-EL].)
at downshifting.
19 • Excessive shift shock on torque • Strong shock is felt when TCC is (See 05-03-24 NO.19
converter clutch (TCC) engaged. EXCESSIVE SHIFT SHOCK
ON TORQUE CONVERTER
CLUTCH (TCC) [AW6A-EL,
AW6AX-EL].)

05-03–5
1890-1U-06H(05-03).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
20 • Noise occurs at idle when vehicle • Transaxle is noisy in all positions and (See 05-03-24 NO.20 NOISE
is stopped in all positions/ranges ranges when vehicle is idling. OCCURS AT IDLE WHEN
VEHICLE IS STOPPED IN ALL
POSITIONS/RANGES [AW6A-
EL, AW6AX-EL].)
21 • Noise occurs at idle when vehicle • Transaxle is noisy in driving ranges (See 05-03-25 NO.21 NOISE
is stopped in D range, or in R when vehicle is idling. OCCURS AT IDLE WHEN
position VEHICLE IS STOPPED IN D
RANGE, OR IN R POSITION
[AW6A-EL, AW6AX-EL].)
22 • No engine braking in 1GR position • Engine speed drops to idle but vehicle (See 05-03-25 NO.22 NO
of M range coasts when accelerator pedal is ENGINE BRAKING IN 1GR
released during cruising at medium to POSITION OF M RANGE
high speeds. [AW6A-EL, AW6AX-EL].)
• Engine speed drops to idle but vehicle
coasts when accelerator pedal is
released when in M range (1GR) at low
vehicle speed.
23 • Transaxle overheats • Burnt smell emitted from the transaxle. (See 05-03-26 NO.23
• Smoke is emitted from the transaxle. TRANSAXLE OVERHEATS
[AW6A-EL, AW6AX-EL].)
24 • Engine stalls when shifted to D • Engine stalls when shifting from N or P (See 05-03-27 NO.24 ENGINE
range, or in R position position to D range or R position at idle. STALLS WHEN SHIFTED TO
D RANGE, OR IN R POSITION
[AW6A-EL, AW6AX-EL].)
25 • Engine stalls when driving at slow • Engine stalls when brake pedal is (See 05-03-27 NO.25 ENGINE
speeds or stopping depressed while driving at low speed or STALLS WHEN DRIVING AT
stopping. SLOW SPEED OR STOPPING
[AW6A-EL, AW6AX-EL].)
26 • Starter does not work • Starter does not work even when P or N (See 05-03-28 NO.26
position is selected. STARTER DOES NOT WORK
[AW6A-EL, AW6AX-EL].)
27 • Gear position indicator light does • Gear position indicator light in (See 05-03-29 NO.27 GEAR
not illuminate in D or M range instrument cluster does not illuminate in POSITION INDICATOR LIGHT
D or M range and ignition switch at ON. DOES NOT ILLUMINATE IN D
OR M RANGE [AW6A-EL,
AW6AX-EL].)
28 • Gear position indicator light • Gear position indicator light in (See 05-03-30 NO.28 GEAR
illuminate in P, R or N range instrument cluster illuminate in P, R or N POSITION INDICATOR LIGHT
range and ignition switch at ON. ILLUMINATE IN P, R OR N
RANGE [AW6A-EL, AW6AX-
EL].)
29 • Does not upshift in M range • Gear position indicator light in (See 05-03-31 NO.29 DOES
instrument cluster illuminates but vehicle NOT UPSHIFT IN M RANGE
does not upshift when selector lever is [AW6A-EL, AW6AX-EL].)
pushed to “+” side.
30 • Does not downshift in M range • Gear position indicator light in (See 05-03-31 NO.30 DOES
instrument cluster illuminates but vehicle NOT DOWNSHIFT IN M
does not downshift when selector lever RANGE [AW6A-EL, AW6AX-
is pushed to “–” side. EL].)

End Of Sie

05-03–6
1890-1U-06H(05-03).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

QUICK DIAGNOSIS CHART [AW6A-EL, AW6AX-EL]
id050310800500

1 Vehicle does not move in D range, or in R position X X X X X

2 Vehicle moves in N position X X X
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged X X
4 Excessive creep X X
5 No creep at all X
6 Low maximum speed and poor acceleration X X X
7 No shifting X X X
8 Does not shift to 6GR X X X X X
9 Abnormal shifting X X X X
10 Frequent shifting X X X X
11 Shift point is high or low X
12 Torque converter clutch (TCC) non-operation X X
13 No kickdown X
14 Engine flares up or slips when upshifting or downshifting X X X
15 Engine flares up or slips when accelerating vehicle X X X
16 Judder upon torque converter clutch (TCC) operation X X X
17 Excessive shift shock from N to D or N to R position/range X X X X 05-03
18 Excessive shift shock is given when upshifting and
downshifting X X X X
19 Excessive shift shock on torque converter clutch (TCC) X X X X
20 Noise occurs at idle when vehicle is stopped in all
positions/ranges X X X
21 Noise occurs at idle when vehicle is stopped in D
range, or in R position X X
22 No engine braking in 1GR position of M range X X
23 Transaxle overheats X X X
24 Engine stalls when shifted to D range, or in R position X
25 Engine stalls when driving at slow speeds or stopping
26 Starter does not work X X X
27 Gear position indicator light does not illuminate in X X X
D or M range
28 Gear position indicator light illuminate in P, R or N range X X
29 Does not upshift in M range X X X
30 Does not downshift in M range X
Electrical system components
Symptom item ATX outer parts
CAN
signal
TR switch initial learning

M range switch
Shift position (to instrument cluster)
Accelerator opening (from PCM)

TR switch

Up switch
Parking mechanism not operating properly

Engine speed (from PCM)

TCM power supply/GND

Garage shift learning is not performed
Not within ignition timing specification
Not within line pressure specification

N position learning is not performed

Not within Idle speed specification
Selector lever is mis-adjisted

Not within ATF amount

Abnormal signal input

Abnormal signal input

Abnormal signal input

No signal input

No signal input

No signal input
Open/short
Open/short
Open/short
Open/short

Cause of trouble

ac9uuw00001210

05-03–7
1890-1U-06H(05-03).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

1 Vehicle does not move in D range, or in R position X X X

2 Vehicle moves in N position X X X
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged
4 Excessive creep
5 No creep at all X X X X X X X X X X X
6 Low maximum speed and poor acceleration X X X X X X X X X X X X X
7 No shifting X X X X X X X X X X X X X
8 Does not shift to 6GR X X X
9 Abnormal shifting X X X X X X X X X X
10 Frequent shifting X X X X X X X X X X
11 Shift point is high or low X X
12 Torque converter clutch (TCC) non-operation X X X
13 No kickdown
14 Engine flares up or slips when upshifting or downshifting X X X X X X X X X X
15 Engine flares up or slips when accelerating vehicle X X X X X X X X X X
16 Judder upon torque converter clutch (TCC) operation X X X X X
17 Excessive shift shock from N to D or N to R position/range X X X X X
18 Excessive shift shock is given when upshifting and
X X X X X X X X X X X X
downshifting
19 Excessive shift shock on torque converter clutch (TCC) X X X X X
20 Noise occurs at idle when vehicle is stopped in all
positions/ranges X X
21 Noise occurs at idle when vehicle is stopped in D
range, or in R position
22 No engine braking in 1GR position of M range X X X X X X
23 Transaxle overheats X
24 Engine stalls when shifted to D range, or in R position X X
25 Engine stalls when driving at slow speeds or stopping X X
26 Starter does not work X
27 Gear position indicator light does not illuminate in
D or M Mrange
28 Gear position indicator light illuminate in P, R or N range
29 Does not upshift in M range
30 Does not downshift in M range X X
Electrical system components
Symptom item
ATX outer parts ATX inner parts
speed sensor
Down switch

Input/turbine

TFT sensor
VSS

Line pressure control solenoid

TCC control solenoid
Starter lock relay

Shift solenoid E
Shift solenoid D
Shift solenoid F
Shift solenoid C
Shift solenoid B
Shift solenoid A
Malfunction signal input
Abnormal signal input

Abnormal signal input

Abnormal signal input

No signal input

No signal input

No signal input

Open/short

Open/short
Open/short

Open/short

Open/short
Open/short

Open/short
Open/short
Open/short

Open/short

Cause of trouble

ac9uuw00001211

05-03–8
1890-1U-06H(05-03).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

1 Vehicle does not move in D range, or in R position X X X X X X X X

2 Vehicle moves in N position X X X X X
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged
4 Excessive creep
5 No creep at all X X X X X X X X X
6 Low maximum speed and poor acceleration X X X X X X X X X X
7 No shifting X X X X X X X X X X
8 Does not shift to 6GR X X X
9 Abnormal shifting X X X X X X X X X X X
10 Frequent shifting X X X X X X X X X X X
11 Shift point is high or low
12 Torque converter clutch (TCC) non-operation X
13 No kickdown
14 Engine flares up or slips when upshifting or downshifting X X X X X X X X X X X
15 Engine flares up or slips when accelerating vehicle X X X X X X X X X X X
16 Judder upon torque converter clutch (TCC) operation X X X
17 Excessive shift shock from N to D or N to R position/range X X X X X X
18 Excessive shift shock is given when upshifting and
downshifting X X X X X X X X X X X
05-03
19 Excessive shift shock on torque converter clutch (TCC) X X X
20 Noise occurs at idle when vehicle is stopped in all
positions/ranges
21 Noise occurs at idle when vehicle is stopped in D
range, or in R position
22 No engine braking in 1GR position of M range X X X X
23 Transaxle overheats X
24 Engine stalls when shifted to D range, or in R position X
25 Engine stalls when driving at slow speeds or stopping X
26 Starter does not work
27 Gear position indicator light does not illuminate in
D or M range
28 Gear position indicator light illuminate in P, R or N range
29 Does not upshift in M range
30 Does not downshift in M range
Hydraulic system components
Symptom item Control valve body
Centrifugal hydraulic pressure clutch is not operating properly

Line pressure control solenoid hydraulic circuit

TCC control solenoid hydraulic circuit

Shift solenoid C hydraulic circuit

Shift solenoid D hydraulic circuit
Shift solenoid A hydraulic circuit
Shift solenoid B hydraulic circuit

Shift solenoid E hydraulic circuit

Shift solenoid F hydraulic circuit
Valve body spool is not operating properly
C1 accumulator is not operating properly
C2 accumulator is not operating properly
C3 accumulator is not operating properly
B1 accumulator is not operating properly
B2 accumulator is not operating properly

ATF cooler is not operating properly

Clogging
Clogging
Clogging
Clogging
Clogging
Clogging
Clogging
Clogging

Cause of trouble

ac9uuw00001212

05-03–9
1890-1U-06H(05-03).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

1 Vehicle does not move in D range, or in R position X X X X

2 Vehicle moves in N position X
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged
4 Excessive creep
5 No creep at all X X
6 Low maximum speed and poor acceleration X X
7 No shifting X
8 Does not shift to 6GR X X X X
9 Abnormal shifting
10 Frequent shifting
11 Shift point is high or low
12 Torque converter clutch (TCC) non-operation
13 No kickdown
14 Engine flares up or slips when upshifting or downshifting X X
15 Engine flares up or slips when accelerating vehicle X X
16 Judder upon torque converter clutch (TCC) operation X X X X X
17 Excessive shift shock from N to D or N to R position/range X X
18 Excessive shift shock is given when upshifting and
X X
downshifting
19 Excessive shift shock on torque converter clutch (TCC) X X X X X
20 Noise occurs at idle when vehicle is stopped in all
positions/ranges
21 Noise occurs at idle when vehicle is stopped in D
range, or in R position
22 No engine braking in 1GR position of M range X X
23 Transaxle overheats
24 Engine stalls when shifted to D range, or in R position X
25 Engine stalls when driving at slow speeds or stopping X
26 Starter does not work
27 Gear position indicator light does not illuminate in
D or M range
28 Gear position indicator light illuminate in P, R or N range
29 Does not upshift in M range
30 Does not downshift in M range

Powertrain
Symptom item
Torque converter is not operating properly
One-way clutch is not operated properly

TCC is not operating properly

TCC is cracking or peeling
Slipping (clutch, brake)
Burnt (clutch, brake)

Cause of trouble

ac9uuw00001213

End Of Sie

05-03–10
1890-1U-06H(05-03).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.1 VEHICLE DOES NOT MOVE IN D RANGE, OR IN R POSITION [AW6A-EL, AW6AX-EL]
id050310800600

1 Vehicle does not move in D range, or in R position

DESCRIPTION • Vehicle does not move when accelerator pedal is depressed.
• If the vehicle does not move in D range or R position, basically, the malfunction is in the ATX. (Vehicle
will move even with a malfunction in the TCM.) Since a malfunction is in the sensor circuit or output
circuit is the cause of the malfunction in the ATX, inspect the sensors, output circuit, and the related
wiring harnesses.
— Clutch slippage, worn (D range-C1 clutch, One-way clutch, R position-C3 clutch, B2 brake)
• Line pressure low
• Shift solenoid C malfunction
• Shift solenoid D malfunction
• Shift solenoid E malfunction
• Line pressure control solenoid malfunction
• Shift solenoid F malfunction
POSSIBLE • Sensor ground malfunction
CAUSE • Body ground malfunction
• Control valve body malfunction
— Selector lever malfunction
— Parking mechanism not operating properly 05-03
— Torque converter malfunction
— N position learning is not performed

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • When the vehicle is stopped on a flat, level Yes Go to the next step.
road and the engine off, does the vehicle No Inspect for parking mechanism.
move when pushed? (in D range or N, R
positions with the brake pedal released)
2 • Start the engine. Yes Inspect or adjust selector lever.
• Does vehicle move when selector lever in (See 05-18-6 SELECTOR LEVER INSPECTION.)
between N position and D range? (See 05-18-7 SELECTOR CABLE ADJUSTMENT.)
Perform N position learning.
(See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
No Go to the next step.
3 • Stop the engine. Yes Replace the ATX (clutch slippage, worn)
• Inspect following solenoid. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
(See 05-17-21 SOLENOID VALVE INSTALLATION [AW6A-EL, AW6AX-EL].)
INSPECTION [AW6A-EL, AW6AX-EL].) No Inspect the coupler component.
— Shift solenoid C If normal, replace the control valve body.
— Shift solenoid D (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Shift solenoid E INSTALLATION [AW6A-EL, AW6AX-EL].)
— Shift solenoid F
— Line pressure control solenoid
• Are these normal?
4 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–11
1890-1U-06H(05-03).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.2 VEHICLE MOVES IN N POSITION [AW6A-EL, AW6AX-EL]
id050310800700

2 Vehicle moves in N position

• Vehicle creeps in N position.
DESCRIPTION
• Vehicle creeps if brake pedal is not depressed in N position.
• If the vehicle moves in N position, basically, the malfunction is in the ATX. Since a malfunction in the
sensor circuit or output circuit is the cause of the malfunction in the ATX, inspect the sensors, output
circuit, and the related wiring harnesses.
— Clutch burnt (C1 clutch, C3 clutch, One-way clutch)
• Line pressure low
• Shift solenoid C malfunction
• Shift solenoid E malfunction
• Line pressure control solenoid malfunction
POSSIBLE • Control valve body malfunction
CAUSE — Selector lever position disparity (Although the selector indicator shows N position, the hydraulic
circuit shows D range or R position)
• N position learning is not performed

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • Does the vehicle creep when selector lever is Yes Go to the next step.
moved slightly in N position? No Inspect and adjust the selector lever.
(See 05-18-6 SELECTOR LEVER INSPECTION.)
(See 05-18-7 SELECTOR CABLE ADJUSTMENT.)
Perform N position learning.
(See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
2 • Inspect following solenoid. Yes Replace the ATX (clutch slippage, worm).
(See 05-17-21 SOLENOID VALVE (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
INSPECTION [AW6A-EL, AW6AX-EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
— Shift solenoid C No Inspect the coupler component.
— Shift solenoid D If normal, replace the control valve body.
• Are these solenoids normal? (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie
NO.3 VEHICLE MOVES IN P POSITION, OR PARKING GEAR DOES NOT DISENGAGE WHEN P IS
DISENGAGED [AW6A-EL, AW6AX-EL]
id050310800800

3 Vehicle moves in P position, or parking gear does not disengage when P is disengaged
• Vehicle rolls on a downward slope in P position.
DESCRIPTION • Tires are locked when P is disengaged. Vehicle does not move in D range, and R position when the
accelerator pedal is depressed, and the engine remains in a stalled condition.
• Parking mechanism malfunction (May have effect on noise or shock from transaxle)
POSSIBLE
• Improper adjustment of selector lever
CAUSE
• If the vehicle moves in N position, perform No.2 “VEHICLE MOVES IN N POSITION”

End Of Sie
NO.4 EXCESSIVE CREEP [AW6A-EL, AW6AX-EL]
id050310800900

4 Excessive creep
DESCRIPTION • Vehicle accelerates in D range, and R position when accelerator pedal is not depressed.
• Engine idle speed is high (transaxle system is not cause of problem)
POSSIBLE
• Go to No.9 “FAST IDLE/RUNS ON”
CAUSE
(See 01-03-28 NO.9 FAST IDLE/RUNS ON [MZI-3.5].)

05-03–12
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SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

End Of Sie

NO.5 NO CREEP AT ALL [AW6A-EL, AW6AX-EL]

id050310801000

5 No creep at all
DESCRIPTION • Vehicle does not move in D range and R position when idling on a flat paved road.
• Either engine output low or there is clutch slippage.
— Clutch burnt (C1 clutch, C3 clutch)
• Line pressure low
• Shift solenoid C malfunction
• Shift solenoid D malfunction
• Shift solenoid E malfunction
• Line pressure control solenoid malfunction
• Shift solenoid F malfunction
• Body ground malfunction
• Control valve body malfunction
POSSIBLE — Transaxle fixed in 3GR or 5GR* (Operation of fail-safe function)
CAUSE • Short or open circuit in wiring harness
• Poor connection of connector
• Malfunction of electronic parts of output and input system
— There is no engine torque 05-03
• Torque converter malfunction

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • Does the vehicle creep in P and/or N Yes Inspect or adjust the selector lever.
position? (See 05-18-6 SELECTOR LEVER INSPECTION.)
(See 05-18-7 SELECTOR CABLE ADJUSTMENT.)
No Go to the next step.
2 • Stop the engine. Yes Go to the next step.
• Inspect following solenoid. No Inspect the coupler component.
(See 05-17-21 SOLENOID VALVE If normal, replace the control valve body.
INSPECTION [AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Shift solenoid C INSTALLATION [AW6A-EL, AW6AX-EL].)
— Shift solenoid D
— Shift solenoid E
— Shift solenoid F
— Line pressure control solenoid
• Are these solenoids normal?
3 • Remove the torque converter. Yes Inspect the ATF condition.
(See 05-17-50 TORQUE CONVERTER • If a large amount of metal specks are found, replace the
REMOVAL/INSTALLATION [AW6A-EL, transaxle.
AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Inspect the torque converter. INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the torque converter normal? • If a large amount of metal specks are not found, replace
the control valve body.
(See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
No Replace the torque converter.
4 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

* : If case of shift solenoid C failure

End Of Sie

05-03–13
1890-1U-06H(05-03).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.6 LOW MAXIMUM SPEED AND POOR ACCELERATION [AW6A-EL, AW6AX-EL]
id050310801100

6 Low maximum speed and poor acceleration

• Vehicle acceleration is poor at start.
DESCRIPTION
• Delayed acceleration when accelerator pedal is depressed while driving.
• If the clutch is stuck or does not stay in 4GR, malfunction is in engine circuit.
— Clutch slippage, burnt (C1 clutch, C2 clutch, C3 clutch, B1 brake)
• Line pressure low
• Incorrect accelerator opening signal
• VSS malfunction
• Input/turbine speed sensor malfunction
• Sensor ground malfunction
• Shift solenoid C malfunction
• Shift solenoid D malfunction
• Shift solenoid E malfunction
• Line pressure control solenoid malfunction
• Shift solenoid F malfunction
POSSIBLE • Body ground malfunction
CAUSE • Control valve body malfunction
— Transaxle fixed in 3GR or 5GR* (Operation of fail-safe function)
• Short or open circuit in wiring harness
• Poor connection of connector
• Malfunction of electronic parts of output and input system
— Insufficient starting torque (Suspected when in-gear, shift control and engine circuit are normal)
• Torque converter malfunction (Poor operation, stuck)

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • With the ignition switch at the ON position, Yes Go to the next step.
does the gear position indicator light No Go to No.27 “GEAR POSITION INDICATOR LIGHT DOES
indication correspond to the selector lever NOT ILLUMINATE IN M RANGE”, or No.28 “GEAR
position? POSITION INDICATOR LIGHT ILLUMINATES IN D RANGE
OR P, N, R POSITIONS”.
2 • Go to No.12 “LACK/LOSS OF POWER Yes Go to the next step.
(ACCELERATION/CRUISE)”. No Repair or replace any malfunctioning parts according to the
(See 01-03-34 NO.12 LACK/LOSS OF inspection results.
POWER-ACCELERATION/CRUISE [MZI-
3.5].)
• Does engine control system normal?
3 • Stop the engine. Yes Go to the next step.
• Inspect following solenoid. No Inspect the coupler component.
(See 05-17-21 SOLENOID VALVE If normal, replace the control valve body.
INSPECTION [AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Shift solenoid C INSTALLATION [AW6A-EL, AW6AX-EL].)
— Shift solenoid D
— Shift solenoid E
— Shift solenoid F
— Line pressure control solenoid
• Are they normal?
4 • Remove the torque converter. Yes Inspect the ATF condition.
(See 05-17-50 TORQUE CONVERTER • If a large amount of metal specks are found, replace the
REMOVAL/INSTALLATION [AW6A-EL, transaxle.
AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Inspect the torque converter. INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the torque converter normal? • If a large amount of metal specks are not found, replace
the control valve body.
(See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
No Replace the torque converter.

05-03–14
1890-1U-06H(05-03).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
5 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

* : If case of shift solenoid C failure

End Of Sie
NO.7 NO SHIFTING [AW6A-EL, AW6AX-EL]
id050310801200

7 No shifting
• Single shift range only.
DESCRIPTION
• Sometimes it shifts correctly.
• When the gear position is fixed in 3GR or 5GR* due to the fail-safe operation, malfunction is in the ATX.
• Perform malfunction diagnosis according to No.6 “LOW MAXIMUM SPEED AND POOR
ACCELERATION”. 05-03
— Clutch burnt (C1 clutch, C2 clutch, C3 clutch, B1 brake)
• Line pressure low
• Incorrect accelerator opening signal
• VSS malfunction
• Input/turbine speed sensor malfunction
• Sensor ground malfunction
POSSIBLE • Shift solenoid C malfunction
CAUSE • Shift solenoid D malfunction
• Shift solenoid E malfunction
• Line pressure control solenoid malfunction
• Shift solenoid F malfunction
• Control valve body malfunction
— 3GR or 5GR* is fixed (Operation in fail-safe function)
• Short or open circuit in wiring harness
• Poor connection of connector
• Poor ground of shift solenoid
• Malfunction of electronic parts of output and input system

* : If case of shift solenoid C failure

End Of Sie

05-03–15
1890-1U-06H(05-03).fm 16 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.8 DOES NOT SHIFT TO 6GR [AW6A-EL, AW6AX-EL]
id050310801300

8 Does not shift to 6GR

• Vehicle does not upshift from 5GR to 6GR even though vehicle speed is increased.
DESCRIPTION • Vehicle does not shift to 6GR even though accelerator pedal is released in D range at 80 km/h {50
mph}.
• Basically, TCC does not operate when the fail-safe is operating. Verify the DTC at first. If the TCC
operates when driving at high speeds only, the malfunction (improper adjustment) is in the M range
switch circuit or TR switch circuit.
Caution
• If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which
may have mixed in with the ATF.

— TCC slippage, burnt

• Line pressure low
• Incorrect accelerator opening signal
• VSS malfunction
• Input/turbine speed sensor malfunction
• Sensor ground malfunction
— TFT sensor malfunction
• Short or open circuit in wiring harness
• Poor connection of connector
POSSIBLE • Sensor malfunction
CAUSE — TR switch malfunction
• Selector lever adjustment incorrect
• TR switch adjustment incorrect
— TCC control solenoid malfunction
• Short or open circuit in wiring harness
• Poor connection of connector
• Solenoid valve stuck
— M range switch malfunction
• Selector lever adjustment incorrect
• Short or open circuit in wiring harness
— Torque converter malfunction
— Control valve body malfunction

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

05-03–16
1890-1U-06H(05-03).fm 17 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 • With the ignition switch at the ON position. Yes Go to the next step.
• Does the gear position indicator light No Go to No.27 “GEAR POSITION INDICATOR LIGHT DOES
indication correspond to selector lever NOT ILLUMINATE IN M RANGE”, or No.28 “GEAR
position? POSITION INDICATOR LIGHT ILLUMINATES IN D RANGE
OR P, N, R POSITIONS”.
2 • Drive the vehicle in D range and inspect Yes Go to the next step.
following: No No shift at all:
— 1–2 shift up and down • Go to No.7 “NO SHIFTING”.
— 2–3 shift up and down Abnormal shift:
— 3–4 shift up and down • Go to No.9 “ABNORMAL SHIFTING”.
— 4–5 shift up and down
— 5–6 shift up and down
• Are all shift-up and shift-down possible?
3 • Stop the engine. Yes Go to the next step.
• Inspect following solenoid. No Inspect for shift solenoid stuck.
(See 05-17-21 SOLENOID VALVE (See 05-17-21 SOLENOID VALVE INSPECTION [AW6A-
INSPECTION [AW6A-EL, AW6AX-EL].) EL, AW6AX-EL].) 05-03
— Shift solenoid C
— Shift solenoid D
— Shift solenoid E
— Shift solenoid F
— Line pressure control solenoid
• Are they normal?
4 • Remove the torque converter. Yes Inspect the ATF condition.
(See 05-17-50 TORQUE CONVERTER • If a large amount of metal specks are found, replace the
REMOVAL/INSTALLATION [AW6A-EL, transaxle.
AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Inspect the torque converter. INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the torque converter normal? • If a large amount of metal specks are not found, replace
the control valve body.
(See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
No Replace the torque converter.
5 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–17
1890-1U-06H(05-03).fm 18 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.9 ABNORMAL SHIFTING [AW6A-EL, AW6AX-EL]
id050310801400

9 Abnormal shifting
DESCRIPTION • Shift incorrectly (incorrect shift pattern).
• There is a malfunction in the signal circuit which controls shifting (Accelerator opening signal, input/
turbine speed sensor, VSS), the control valve is stuck, or the clutch circuit is stuck.
— Clutch slippage, burnt (C1 clutch, C2 clutch, C3 clutch, B1 brake)
• Line pressure low
• Incorrect accelerator opening signal
• VSS malfunction
• Input/turbine speed sensor malfunction
• Sensor ground malfunction
• Shift solenoid C malfunction
• Shift solenoid D malfunction
POSSIBLE • Shift solenoid E malfunction
CAUSE • Line pressure control solenoid malfunction
• TCC control solenoid malfunction
• Shift solenoid F malfunction
• Body ground malfunction
• Control valve body malfunction
• TR switch adjustment incorrect

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • Inspect for continuity between the TCM Yes Go to the next step.
terminal A9 and battery negative terminal. No Repair or replace ground circuit.
• Is there continuity?
2 • Inspect following shift solenoids. Yes Inspect the TCM terminal for bend, damage, corrosion or
(See 05-17-21 SOLENOID VALVE poor contact.
INSPECTION [AW6A-EL, AW6AX-EL].) No Inspect the coupler component.
— Shift solenoid C If normal, replace the control valve body.
— Shift solenoid D (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— Shift solenoid E INSTALLATION [AW6A-EL, AW6AX-EL].)
— Line pressure control solenoid
— TCC control solenoid
— Shift solenoid F
• Are they normal?
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie
NO.10 FREQUENT SHIFTING [AW6A-EL, AW6AX-EL]
id050310801500

10 Frequent shifting
DESCRIPTION • Downshifting occurs suddenly even when accelerator pedal is depressed slightly in D range.
• The malfunctioning circuit is basically the same as No.9 “ABNORMAL SHIFTING”. However, a
POSSIBLE malfunction of the input signal to the accelerator pedal position sensor, APP sensor, input/turbine speed
CAUSE sensor, VSS (including the sensor ground, sensor wiring harness and connector), or clutch slippage
(clutch stuck, low pressure in line) may also be the cause.

End Of Sie

05-03–18
1890-1U-06H(05-03).fm 19 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.11 SHIFT POINT IS HIGH OR LOW [AW6A-EL, AW6AX-EL]
id050310801600

11 Shift point is high or low

• Shift point considerably different from automatic shift diagram.
DESCRIPTION • Shift delays when accelerating.
• Shift occurs quickly when accelerating and engine speed does not increase.
• If the transaxle does not shift abnormally, there is a malfunction of the input signal to the APP sensor,
POSSIBLE input/turbine speed sensor, or VSS.
CAUSE • If the engine speed is high or low, regardless of normal shifting, inspect the tachometer.
• Verify that the output signals of the accelerator pedal position sensor and APP sensor change linearly.

End Of Sie
NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION [AW6A-EL, AW6AX-EL]
id050310801700

12 Torque converter clutch (TCC) non-operation

DESCRIPTION • TCC does not operate when vehicle reaches TCC operation range.
• Basically, TCC does not operate when the fail-safe is operating. Verify the DTC at first. If the TCC
operates when driving at high speeds only, the malfunction (improper adjustment) is in the M range
switch circuit or TR switch circuit.
05-03
Caution
• If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which
may have mixed in with the ATF.

• TCC slippage, burnt

— Line pressure low
• Incorrect accelerator opening signal
• Input/turbine speed sensor malfunction
• VSS malfunction
POSSIBLE
• Output solenoid valve system malfunction (Sticking)
CAUSE
• TCC control solenoid malfunction
• Control valve body system malfunction (Poor operation, sticking)
• TCC hydraulic pressure system malfunction
• Accelerator pedal position sensor malfunction (Not operating linearly)
• Input/turbine speed sensor or VSS malfunction
• Operation of fail-safe function.
— Short to power or ground at TCC control solenoid related circuit.

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • With the ignition switch at the ON position. Yes Go to the next step.
• Does the gear position indicator light No Go to No.27 “GEAR POSITION INDICATOR LIGHT DOES
indication correspond to the selector lever NOT ILLUMINATE IN M RANGE”, or No.28 “GEAR
position? POSITION INDICATOR LIGHT ILLUMINATES IN D RANGE
OR P, N, R POSITIONS”.
2 • Disconnect the TCM. Yes Go to the next step.
• Is the resistance between the TCM ground No Repair open ground circuit.
terminal A9 and the body ground less than
5.0 ohms?
3 • Inspect the line pressure control solenoid. Yes Go to the next step.
(See 05-17-21 SOLENOID VALVE No Replace the control valve body.
INSPECTION [AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Is the line pressure control solenoid normal? INSTALLATION [AW6A-EL, AW6AX-EL].)

05-03–19
1890-1U-06H(05-03).fm 20 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
4 • Remove the torque converter. Yes Inspect the ATF condition.
(See 05-17-50 TORQUE CONVERTER • If a large amount of metal specks are found, replace the
REMOVAL/INSTALLATION [AW6A-EL, transaxle.
AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Inspect the torque converter. INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the torque converter normal? • If a large amount of metal specks are not found, replace
the control valve body.
(See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
No Replace the torque converter.
5 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie
NO.13 NO KICKDOWN [AW6A-EL, AW6AX-EL]
id050310801800

13 No kickdown
DESCRIPTION • Does not downshift when accelerator pedal is fully depressed within kickdown range.
• If transaxle does not downshift though shifting is normal, the malfunction is in the accelerator pedal
POSSIBLE
position sensor and accelerator pedal position sensor circuits (including sensor ground, sensor wiring
CAUSE
harness and connector).

End Of Sie
NO.14 ENGINE FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING [AW6A-EL, AW6AX-EL]
id050310801900

14 Engine flares up or slips when upshifting or downshifting

• When the accelerator pedal is depressed for acceleration from standstill, engine speed increases but
the vehicle speed increases slowly.
DESCRIPTION
• When the accelerator pedal is depressed while driving, engine speed increases but the vehicle speed
does not.
• There is clutch slippage because the clutch is stuck or the line pressure is low.
— Clutch stuck, slippage (C1 clutch, C2 clutch, C3 clutch, B1 brake)
• Line pressure low
• Incorrect accelerator opening signal
• VSS malfunction
• Input/turbine speed sensor malfunction
• Sensor ground malfunction
• Shift solenoid C malfunction
• Shift solenoid D malfunction
POSSIBLE • Shift solenoid E malfunction
CAUSE • Line pressure control solenoid malfunction
• TCC control solenoid malfunction
• Shift solenoid F malfunction
• Body ground malfunction
• Control valve body malfunction

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

05-03–20
1890-1U-06H(05-03).fm 21 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

Diagnostic procedure
STEP INSPECTION ACTION
1 • Is the line pressure normal? Yes Go to the next step.
(See 05-17-3 MECHANICAL SYSTEM No Repair or replace any malfunctioning parts according to the
TEST [AW6A-EL, AW6AX-EL].) inspection results.
2 • Is shift point normal? Yes Go to the next step.
(See 05-17-7 ROAD TEST [AW6A-EL, No Go to No.9 “ABNORMAL SHIFTING”.
AW6AX-EL].)
3 • Stop the engine. Yes Inspect the ATF condition.
• Inspect following solenoids. • If a large amount of metal specks are found, replace the
(See 05-17-21 SOLENOID VALVE transaxle.
INSPECTION [AW6A-EL, AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
— Shift solenoid C INSTALLATION [AW6A-EL, AW6AX-EL].)
— Shift solenoid D • If a large amount of metal specks are not found, replace
— Shift solenoid E the control valve body.
— Line pressure control solenoid (See 05-17-42 CONTROL VALVE BODY REMOVAL/
— TCC control solenoid INSTALLATION [AW6A-EL, AW6AX-EL].)
— Shift solenoid F No Replace the control valve body.
• Are they normal? (See 05-17-42 CONTROL VALVE BODY REMOVAL/ 05-03
INSTALLATION [AW6A-EL, AW6AX-EL].)
4 • Inspect the coupler component for open or Yes Go to the next step.
short. No Replace the coupler component.
• Are coupler component normal?
5 • Inspect the ATF condition. Yes Replace the transaxle.
• Are a large amount of specks found? (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
No Replace the control valve body.
(See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
6 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie
NO.15 ENGINE FLARES UP OR SLIPS WHEN ACCELERATING VEHICLE [AW6A-EL, AW6AX-EL]
id050310802000

15 Engine flares up or slips when accelerating the vehicle

• Engine flares up when the accelerator pedal is depressed for upshifting.
DESCRIPTION
• Engine flares up suddenly when the accelerator pedal is depressed for downshifting.
• The malfunction is basically the same as for No.14 “ENGINE FLARES UP OR SLIPS WHEN
POSSIBLE
UPSHIFTING OR DOWNSHIFTING”.
CAUSE
— If conditions for No.14 worsen, the malfunction will develop to No.15.

End Of Sie

05-03–21
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SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.16 JUDDER UPON TORQUE CONVERTER CLUTCH (TCC) OPERATION [AW6A-EL, AW6AX-EL]
id050310802100

16 Judder upon torque converter clutch (TCC) operation

DESCRIPTION • Vehicle jolts when TCC is engaged.
• Poor TCC engagement due to either slippage because the TCC piston is stuck or the line pressure is
low.
Caution
• If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which
may have mixed in with the ATF.

— TCC slippage, burnt

POSSIBLE • Line pressure low
CAUSE • Incorrect accelerator opening signal
• VSS malfunction
• Input/turbine speed sensor malfunction
• Sensor ground malfunction
• TCC control solenoid malfunction
• Control valve body malfunction
— Torque converter malfunction
— Centrifugal hydraulic pressure clutch is not operating properly

End Of Sie
NO.17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGE [AW6A-EL, AW6AX-EL]
id050310802200

17 Excessive shift shock from N to D or N to R position/range

DESCRIPTION • Strong shock felt when shifting from N to D or N to R position/range at idle.
• Shift shock may worsen when the fail-safe is operating. If no DTC is output, the shift shock may worsen
due to poor operation of the control valve body or sticking of the clutch.
— Clutch burnt (N→D: C1 clutch, N→R: C3 clutch or B2 brake)
• Line pressure low
• Incorrect accelerator opening signal
• TFT sensor malfunction
• Sensor ground malfunction
• Shift solenoid C malfunction
• Shift solenoid E malfunction
• Line pressure control solenoid malfunction
POSSIBLE • Control valve body malfunction
CAUSE — Poor hydraulic operation (Malfunction in range change)
— Idle speed high
— Poor tightening torque of engine mount, exhaust mount
— Line pressure high
— Garage shift control is not learned
• Initial learning did not perform

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • Does the shift shock occur only when the Yes Go to the next step.
engine is cold? No Go to Step 3.
2 • Inspect the TFT sensor and related wiring Yes Go to the next step.
harness: vibration, intermittent open/short No Repair or replace part if necessary.
circuit.
(See 05-17-13 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION [AW6A-EL, AW6AX-EL].)
• Is it normal?
3 • Perform the initial learning procedure. Yes Troubleshooting is completed.
(See 05-03-23 Initial Learning.) No Go to the next step.
• Does symptom eliminate?
4 • Is the line pressure normal? Yes Go to the next step.
(See 05-17-3 MECHANICAL SYSTEM No Repair or replace any malfunctioning parts according to the
TEST [AW6A-EL, AW6AX-EL].) inspection results.

05-03–22
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SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

STEP INSPECTION ACTION
5 • Is stall speed normal? Yes Go to the next step.
(See 05-17-3 MECHANICAL SYSTEM No Repair or replace any malfunctioning parts according to the
TEST [AW6A-EL, AW6AX-EL].) inspection results.
6 • Stop the engine. Yes Inspect the ATF condition.
• Inspect following solenoids. • If a large amount of metal specks are found, replace the
(See 05-17-21 SOLENOID VALVE transaxle.
INSPECTION [AW6A-EL, AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
— Line pressure control solenoid INSTALLATION [AW6A-EL, AW6AX-EL].)
— Shift solenoid C • If a large amount of metal specks are not found, replace
— Shift solenoid E the control valve body.
• Are they normal? (See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
No • Replace the control valve body.
(See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
7 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform 05-03
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

Initial Learning

Warning
• When performing initial learning, be aware of other vehicles, people, and other impediments in
order to avoid an accident.

Note
• While self-learning control gradually reduces shock during normal driving, initial learning is performed to
initially learn a certain amount of driving conditions.

1. Warm-up
• Increase the ATF temperature by leaving the vehicle idling or performing city driving. Verify that the ATF
temperature is between 66—110 °C {151—230 °F}. If the ATF temperature is outside this range, work to
bring it inside the range.

Caution
• Do not raise the ATF temperature by stalling the engine.

Note
• If the ATF temperature is not between 66—110 °C {151—230 °F}, initial learning cannot be performed.
Before learning, inspect for variable shift shock.

2. Garage shift learning

• With the vehicle standing still, depress the brake pedal and keep the selector lever in N position for 3 s.
Then, shift the selector lever from the N position into D range, and maintain in this condition for 3 s. Repeat
this procedure 5 times. Then repeat it 5 times in the same way for R position.
3. Gear shift control learning
• In D range, with the accelerator opening between 25—30%, drive until you reach 6th gear and a vehicle
speed of 80 km/h {50 mph} or higher. Then, release the accelerator pedal and coast, and bring the vehicle
to a stop in at least 60 s. Repeat this procedure 10 times.
4. Inspect learning results
• Verify that variable speed shock and shift shock have decreased compared to the conditions before
learning.
End Of Sie

05-03–23
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SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.18 EXCESSIVE SHIFT SHOCK IS GIVEN WHEN UPSHIFTING AND DOWNSHIFTING [AW6A-EL, AW6AX-
EL]
id050310802300

18 Excessive shift shock is given when upshifting and downshifting

• Excessive shift shock is felt when depressing the accelerator pedal at upshifting.
DESCRIPTION
• During cruising, excessive shift shock is felt when depressing accelerator pedal at downshifting.
• Shift shock may worsen when the fail-safe is operating. The shift shock may worsen if the accelerator
pedal position sensor, APP sensor, input/turbine speed sensor, or VSS signal malfunctions.
— Clutch slippage, burnt (C1 clutch, C2 clutch, C3 clutch, B1 brake)
• Line pressure low, high
• Incorrect accelerator opening signal
• VSS malfunction
• Input/turbine speed sensor malfunction
• TFT sensor malfunction
POSSIBLE
• Shift solenoid C malfunction
CAUSE
• Shift solenoid D malfunction
• Shift solenoid E malfunction
• Line pressure control solenoid malfunction
• TCC control solenoid malfunction
• Shift solenoid F malfunction
• Body ground and sensor ground malfunction
• Control valve body malfunction
— Poor hydraulic operation (Malfunction in range change)

End Of Sie
NO.19 EXCESSIVE SHIFT SHOCK ON TORQUE CONVERTER CLUTCH (TCC) [AW6A-EL, AW6AX-EL]
id050310802400

19 Excessive shift shock on torque converter clutch (TCC)

DESCRIPTION • Strong shock is felt when the TCC is engaged.
POSSIBLE • The troubleshooting flow is the same as No.16 “JUDDER UPON TORQUE CONVERTER CLUTCH
CAUSE (TCC) OPERATION”.

End Of Sie
NO.20 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN ALL POSITIONS/RANGES [AW6A-EL,
AW6AX-EL]
id050310802500

20 Noise occurs at idle when vehicle is stopped in all positions/ranges

DESCRIPTION • Transaxle is noisy in all positions and ranges when the vehicle is idling.
• The malfunction is in the pressure solenoid or oil pump which causes a high-pitched noise to be emitted
from the transaxle at idle.

Note
• If a noise is emitted during shifting only, the malfunction is in the C1 clutch, C2 clutch, C3 clutch
POSSIBLE
or B1 brake.
CAUSE
• If a noise is emitted during shifting at certain gears only or during deceleration only, it is gear
noise.
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • Inspect engine condition. Yes Go to appropriate symptom troubleshooting.
• Is there any engine concern (e.g. Rough (See 01-03-3 ENGINE SYMPTOM TROUBLESHOOTING
idle)? [MZI-3.5].)
No Replace basic inspection and repair or replace any
malfunctioning parts according to the inspection result
2 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–24
1890-1U-06H(05-03).fm 25 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.21 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN D RANGE, OR IN R POSITION [AW6A-EL,
AW6AX-EL]
id050310802600

21 Noise occurs at idle when vehicle is stopped in D range, or in R position

DESCRIPTION • Transaxle is noisy in driving ranges when vehicle idling.
• Although the malfunction is basically the same as No.20 “NOISE OCCURS AT IDLE WHEN VEHICLE
POSSIBLE
IS STOPPED IN ALL POSITIONS/RANGES”, other causes may include selector lever position disparity
CAUSE
or TR switch position disparity.

End Of Sie
NO.22 NO ENGINE BRAKING IN 1GR POSITION OF M RANGE [AW6A-EL, AW6AX-EL]
id050310802700

22 No engine braking in 1GR position of M range

• Engine speed drops to idle but the vehicle coasts when the accelerator pedal is released during
cruising at medium to high speeds.
DESCRIPTION
• Engine speed drops to idle but the vehicle coasts when accelerator pedal is released when in M range
(1GR) at low vehicle speed.
• Clutch slippage, burnt (B2 brake) 05-03
— Line pressure low
• VSS malfunction
• Input/turbine speed sensor malfunction
• Shift solenoid A or B malfunction
POSSIBLE • Sensor ground malfunction
CAUSE • Control valve body malfunction

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • Do the following symptoms occur Yes Go to No.14 “ENGINE FLARES UP OR SLIPS WHEN
concurrently? UPSHIFTING OR DOWNSHIFTING”, or No.15 “ENGINE
— Engine flares up or slips during FLARES UP OR SLIPS WHEN ACCELERATING
acceleration VEHICLE”.
— Engine flares up or slips when shifting No Go to the next step.
2 • Stop the engine. Yes Inspect the ATF condition.
• Inspect following solenoids. • If a large amount of metal specks are found, replace the
(See 05-17-21 SOLENOID VALVE transaxle.
INSPECTION [AW6A-EL, AW6AX-EL].) (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
— Shift solenoid A INSTALLATION [AW6A-EL, AW6AX-EL].)
— Shift solenoid B • If a large amount of metal specks are not found, replace
• Are the normal? the control valve body.
(See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
No Replace the control valve body.
(See 05-17-42 CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–25
1890-1U-06H(05-03).fm 26 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.23 TRANSAXLE OVERHEATS [AW6A-EL, AW6AX-EL]
id050310802800

23 TRANSAXLE OVERHEATS
• Burnt smell emitted from transaxle.
DESCRIPTION
• Smoke emitted from transaxle.
• The malfunction is restricted to the hindrance of coolant at the oil cooler. In addition, overheating of the
transaxle may be caused by a malfunction of the TFT sensor.
— Line pressure low
• ATF level low
• Incorrect accelerator opening signal
— Oil cooler malfunction (Foreign material mixed in with ATF)
POSSIBLE — TFT sensor malfunction
CAUSE — Excessive amount of ATF

Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • Is the line pressure normal? Yes Go to the next step.
(See 05-17-3 MECHANICAL SYSTEM No Repair or replace any malfunctioning parts according to the
TEST [AW6A-EL, AW6AX-EL].) inspection results.
2 • Is stall speed normal? Yes Go to the next step.
(See 05-17-3 MECHANICAL SYSTEM No Repair or replace any malfunctioning parts according to the
TEST [AW6A-EL, AW6AX-EL].) inspection results.
3 • Inspect the TFT sensor and related wiring Yes Go to the next step.
harness: vibration, intermittent open/short No Repair or replace part if necessary.
circuit
(See 05-17-13 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION [AW6A-EL, AW6AX-EL].)
• Is it normal?
4 • Inspect the line pressure control solenoid. Yes Go to the next step.
(See 05-17-21 SOLENOID VALVE No Replace the control valve body.
INSPECTION [AW6A-EL, AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Is it normal? INSTALLATION [AW6A-EL, AW6AX-EL].)
5 • Inspect for bending, damage, corrosion or Yes Replace the transaxle.
kinks of the oil cooler pipes. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
• Are oil cooler pipes normal? INSTALLATION [AW6A-EL, AW6AX-EL].)
No Replace any malfunctioning parts.
6 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–26
1890-1U-06H(05-03).fm 27 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.24 ENGINE STALLS WHEN SHIFTED TO D RANGE, OR IN R POSITION [AW6A-EL, AW6AX-EL]
id050310802900

24 Engine stalls when shifted to D range, or in R position

DESCRIPTION • Engine stalls when shifting from N or P position to D range or R position at idle.
• The malfunction is on the engine control side (e.g. electronic controlled throttle system). Otherwise, the
malfunction is in the input/turbine speed sensor (engine sometimes starts) or the TCC circuit (engine
always stalls).
POSSIBLE
CAUSE Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • Go to symptom troubleshooting No.5 Yes Go to the next step.
“ENGINE STALLS-AFTER START/AT IDLE”. No Repair or replace any malfunctioning parts according to the
(See 01-03-16 NO.5 ENGINE STALLS- inspection results.
AFTER START/AT IDLE [MZI-3.5].)
05-03
• Is the engine control system normal?
2 • Remove the torque converter. Yes Inspect for bending, damage, corrosion or kinks of the oil
(See 05-17-50 TORQUE CONVERTER cooler pipes.
REMOVAL/INSTALLATION [AW6A-EL, • If normal, replace the control valve body.
AW6AX-EL].) (See 05-17-42 CONTROL VALVE BODY REMOVAL/
• Inspect the torque converter. INSTALLATION [AW6A-EL, AW6AX-EL].)
• Is the torque converter normal? • If problem remains, replace the transaxle.
(See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
No Replace the torque converter.
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie
NO.25 ENGINE STALLS WHEN DRIVING AT SLOW SPEED OR STOPPING [AW6A-EL, AW6AX-EL]
id050310803000

25 Engine stalls when driving at slow speeds or stopping

DESCRIPTION • Engine stalls when the brake pedal is depressed while driving at low speed or stopping.
• The malfunction is in the engine control system (e.g. Fuel injection control, electronic controlled throttle
system)
POSSIBLE Note
CAUSE
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • Go to symptom troubleshooting No.10 “LOW Yes Go to No.24 “ENGINE STALLS WHEN SHIFTED TO D
IDLE/STALLS DURING DECELERATION”. RANGE, OR IN R POSITION”.
(See 01-03-29 NO.10 LOW IDLE/STALLS No Repair or replace any malfunctioning parts according to the
DURING DECELERATION [MZI-3.5].) inspection results.
• Is the engine control system normal?
2 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–27
1890-1U-06H(05-03).fm 28 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.26 STARTER DOES NOT WORK [AW6A-EL, AW6AX-EL]
id050310803100

26 Starter does not work

DESCRIPTION • Starter does not work even when in P or N position.
• Selector lever mis-adjustment
• TR switch malfunction
POSSIBLE
• N position learning is not performed.
CAUSE
• Transaxle operates in fail-safe function (Starter lock system related circuit open or short)
• Immobilizer system operating or system malfunction.

Diagnostic procedure
STEP INSPECTION ACTION
1 • Perform the N position learning. Yes Troubleshooting is completed.
(See 05-17-26 TCM REMOVAL/ If the other symptom occurs, go to applicable
INSTALLATION [AW6A-EL, AW6AX-EL].) troubleshooting procedure.
• Does the problem eliminate? No Go to the next step.
2 • Inspect the TR switch. Yes Go to engine system troubleshooting No.3 “WILL NOT
(See 05-17-13 TRANSAXLE RANGE (TR) CRANK” troubleshooting procedure.
SWITCH INSPECTION [AW6A-EL, AW6AX- No Replace the TR switch and perform initial learning
EL].) procedure.
• Is the TR switch normal? (See 05-03-22 NO.17 EXCESSIVE SHIFT SHOCK FROM N
TO D OR N TO R POSITION/RANGE [AW6A-EL, AW6AX-
EL].)
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–28
1890-1U-06H(05-03).fm 29 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.27 GEAR POSITION INDICATOR LIGHT DOES NOT ILLUMINATE IN D OR M RANGE [AW6A-EL, AW6AX-
EL]
id050310808800

27 Gear position indicator light does not illuminate in D or M range

• Gear position indicator light in instrument cluster does not illuminate in D or M range and ignition switch
DESCRIPTION
at ON.
• M range switch, TR switch, instrument cluster, or related wiring harness malfunction

POSSIBLE Note
CAUSE • Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • With the ignition switch at ON, Yes Go to the next step.
When selector lever is moved, does selector No Check value at the following.
illumination indicate synchronized position to TCM terminal voltage:
lever location? 05-03
• 1U (TR switch)
Repair or replace any malfunctioning parts.
• Inspect the voltage at TCM terminal 1K (M Yes Go to the next step.
range switch). No Repair or replace any malfunctioning part.
2 (See 05-17-22 TCM INSPECTION [AW6A-
EL, AW6AX-EL].)
• Is voltage normal?
• Inspect the instrument cluster. Yes Go to the next step.
(See 09-22-5 INSTRUMENT CLUSTER No Repair or replace any malfunctioning part.
3
INSPECTION.)
• Is instrument cluster normal?
• Disconnect the TCM and instrument cluster Yes Repair or replace harness for short to ground, then go to the
connector. next step.
• Turn the ignition switch off. No Go to the next step.
• Check continuity between the following
circuits:
— TCM terminal A6 and body ground
4
— TCM terminal A14 and body ground
— Instrument cluster terminal 1W and body
ground
— Instrument cluster terminal 1X and body
ground
• Is there continuity?
• Disconnect the TCM and instrument cluster Yes Go to the next step.
connector. No Repair or replace harness for open circuit, then go to the
• Turn the ignition switch off. next step.
• Check continuity between the following
circuits:
5
— TCM terminal A6 and instrument cluster
terminal 1W
— TCM terminal A14 and instrument cluster
terminal 1X
• Is there continuity?
6 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–29
1890-1U-06H(05-03).fm 30 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.28 GEAR POSITION INDICATOR LIGHT ILLUMINATE IN P, R OR N RANGE [AW6A-EL, AW6AX-EL]
id050310812900

28 Gear position indicator light illuminate in P, R or N range

• Gear position indicator light in instrument cluster illuminates in P, R or N range and ignition switch at
DESCRIPTION
ON.
• M range switch, TR switch, instrument cluster, or related wiring harness malfunction

POSSIBLE Note
CAUSE • Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-4 BASIC
INSPECTION [AW6A-EL, AW6AX-EL].)

Diagnostic procedure
STEP INSPECTION ACTION
1 • With the ignition switch at ON, Yes Go to the next step.
When selector lever is moved, does selector No Check value at the following.
illumination indicate synchronized position to TCM terminal voltage:
lever location? • 1U (TR switch)
Repair or replace any malfunctioning parts.
• Inspect the voltage at TCM terminal 1K (M Yes Go to the next step.
range switch). No Repair or replace any malfunctioning part.
2 (See 05-17-22 TCM INSPECTION [AW6A-
EL, AW6AX-EL].)
• Is voltage normal?
Inspect the instrument cluster. Yes Go to the next step.
(See 09-22-5 INSTRUMENT CLUSTER No Repair or replace any malfunctioning part.
3
INSPECTION.)
Is instrument cluster normal?
• Disconnect the TCM and instrument cluster Yes Repair or replace harness for short to ground, then go to the
connector. next step.
• Turn the ignition switch off. No Go to the next step.
• Check continuity between the following
circuits:
— TCM terminal A6 and body ground
4
— TCM terminal A14 and body ground
— Instrument cluster terminal 1W and body
ground
— Instrument cluster terminal 1X and body
ground
• Is there continuity?
• Disconnect the TCM and instrument cluster Yes Go to the next step.
connector. No Repair or replace harness for open circuit, then go to the
• Turn the ignition switch off. next step.
• Check continuity between the following
circuits:
5
— TCM terminal A6 and instrument cluster
terminal 1W
— TCM terminal A14 and instrument cluster
terminal 1X
• Is there continuity?
6 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–30
1890-1U-06H(05-03).fm 31 ページ ２００６年１２月１９日　火曜日　午前１１時５１分

SYMPTOM TROUBLESHOOTING [AW6A-EL, AW6AX-EL]

NO.29 DOES NOT UPSHIFT IN M RANGE [AW6A-EL, AW6AX-EL]
id050310803400

29 Does not upshift in M range

• Gear position indicator light in instrument cluster illuminates, but the vehicle does not upshift when the
DESCRIPTION
selector lever is pushed to “+” side.
POSSIBLE • Up switch or related wiring harness malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 Inspect the voltage at the TCM terminal A3. Yes Inspect the instrument cluster.
(See 05-17-22 TCM INSPECTION [AW6A-EL, No Inspect the up switch.
AW6AX-EL].) • If the up switch is normal, inspect for continuity between
Is the voltage normal? the up switch and TCM terminal A3.
2 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis. 05-03
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie
NO.30 DOES NOT DOWNSHIFT IN M RANGE [AW6A-EL, AW6AX-EL]
id050310803500

30 Does not downshift in M range

• Gear position indicator light in instrument cluster illuminates, but the vehicle does not downshift when
DESCRIPTION
the selector lever is pushed to “–” side.
POSSIBLE • Down switch or related wiring harness malfunction
CAUSE

Diagnostic procedure
STEP INSPECTION ACTION
1 Inspect the voltage at the TCM terminal A4. Yes Inspect the instrument cluster.
(See 05-17-22 TCM INSPECTION [AW6A-EL, No Inspect the down switch.
AW6AX-EL].) • If the down switch is normal, inspect for continuity
Is the voltage normal? between the down switch and TCM terminal A4.
2 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.

End Of Sie

05-03–31
1890-1U-06H(05-17).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

05-17 AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]
AUTOMATIC TRANSAXLE TCM INSPECTION
LOCATION INDEX [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–22
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–2 TR Switch Operating Inspection . . . . . . 05-17–22
MECHANICAL SYSTEM TEST Control Module Inspection . . . . . . . . . . 05-17–22
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–3 TCM REMOVAL/INSTALLATION
Mechanical System [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–26
Test Preparation . . . . . . . . . . . . . . . . . 05-17–3 Neutral Position Learning . . . . . . . . . . . 05-17–29
Line Pressure Test . . . . . . . . . . . . . . . . 05-17–4 OIL SEAL (MANUAL SHAFT)
Stall Test . . . . . . . . . . . . . . . . . . . . . . . 05-17–6 REPLACEMENT
Time Lag Test . . . . . . . . . . . . . . . . . . . 05-17–6 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–30
ROAD TEST AUTOMATIC TRANSAXLE
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–7 REMOVAL/INSTALLATION
Road Test Preparation . . . . . . . . . . . . . 05-17–7 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–30
Shift Diagram . . . . . . . . . . . . . . . . . . . . 05-17–8 Torque Converter Nuts
D Range Test . . . . . . . . . . . . . . . . . . . . 05-17–9 Removal Note . . . . . . . . . . . . . . . . . . . 05-17–34
M Range Test . . . . . . . . . . . . . . . . . . . . 05-17–11 No.1 Engine Mount 05-17
P Position Test . . . . . . . . . . . . . . . . . . . 05-17–11 Removal Note . . . . . . . . . . . . . . . . . . . 05-17–34
AUTOMATIC TRANSAXLE FLUID No.4 Engine Mount Bracket
(ATF) INSPECTION Removal Note . . . . . . . . . . . . . . . . . . . 05-17–35
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–11 Transaxle Removal Note . . . . . . . . . . . . 05-17–36
Automatic Transaxle Fluid (ATF) Transaxle Installation Note . . . . . . . . . . 05-17–36
Condition Inspection . . . . . . . . . . . . . 05-17–11 No.4 Engine Mount Bracket
Automatic Transaxle Fluid (ATF) Installation Note . . . . . . . . . . . . . . . . . 05-17–37
Level Inspection . . . . . . . . . . . . . . . . . 05-17–12 No.1 Engine Mount
AUTOMATIC TRANSAXLE FLUID Installation Note . . . . . . . . . . . . . . . . . 05-17–37
(ATF) REPLACEMENT Torque Converter Nuts
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–12 Installation Note . . . . . . . . . . . . . . . . . 05-17–38
TRANSAXLE RANGE (TR) Selector Cable Installation Note . . . . . . 05-17–39
SWITCH INSPECTION OIL SEAL (DIFFERENTIAL)
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–13 REPLACEMENT
TRANSAXLE FLUID TEMPERATURE [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–39
(TFT) SENSOR INSPECTION Transaxle Case Side . . . . . . . . . . . . . . . 05-17–39
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–13 Converter Housing Side (2WD). . . . . . . 05-17–40
On-Vehicle Inspection . . . . . . . . . . . . . 05-17–13 Converter Housing Side (AWD) . . . . . . 05-17–41
Off-Vehicle Inspection . . . . . . . . . . . . . 05-17–13 DIFFERENTIAL GEAR O-RING
TRANSAXLE FLUID TEMPERATURE REPLACEMENT
(TFT) SENSOR [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–42
REMOVAL/INSTALLATION CONTROL VALVE BODY
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–14 REMOVAL/INSTALLATION
INPUT/TURBINE SPEED SENSOR [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–42
INSPECTION On-Vehicle Removal . . . . . . . . . . . . . . . 05-17–42
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–16 On-Vehicle Installation. . . . . . . . . . . . . . 05-17–46
On-Vehicle Inspection . . . . . . . . . . . . . 05-17–16 OIL SEAL (OIL PUMP) REPLACEMENT
Off-Vehicle Inspection . . . . . . . . . . . . . 05-17–16 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–50
INPUT/TURBINE SPEED SENSOR TORQUE CONVERTER
REMOVAL/INSTALLATION REMOVAL/INSTALLATION
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–18 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–50
VEHICLE SPEED SENSOR (VSS) OIL COOLER FLUSHING
INSPECTION [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–51
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–18 OIL COOLER REMOVAL/INSTALLATION
On-Vehicle Inspection . . . . . . . . . . . . . 05-17–18 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–52
Off-Vehicle Inspection . . . . . . . . . . . . . 05-17–19 Radiator (In Tank Oil Cooler)
VEHICLE SPEED SENSOR (VSS) Installation Note . . . . . . . . . . . . . . . . . 05-17–54
REMOVAL/INSTALLATION Oil Pipe, Hose Clamp, Oil Hose
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–20 Installation Note . . . . . . . . . . . . . . . . . 05-17–54
SOLENOID VALVE INSPECTION OIL COOLER
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-17–21 DISASSEMBLY/ASSEMBLY
Resistance Inspection [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–55
(On-Vehicle Inspection) . . . . . . . . . . . 05-17–21 Radiator Outer Tank (In Tank Oil Cooler)
Continuity Inspection Removal Note . . . . . . . . . . . . . . . . . . . 05-17–55
(On-Vehicle Inspection) . . . . . . . . . . . 05-17–21 Radiator Outer Tank (In Tank Oil Cooler)
Installation Note . . . . . . . . . . . . . . . . . 05-17–56

05-17–1
1890-1U-06H(05-17).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

DRIVE PLATE REMOVAL/INSTALLATION Drive Plate Mounting Bolts
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-17–58 Removal Note. . . . . . . . . . . . . . . . . . . 05-17–58
Drive Plate Installation Note . . . . . . . . . 05-17–58

End of Toc
AUTOMATIC TRANSAXLE LOCATION INDEX [AW6A-EL, AW6AX-EL]
WM: AUTOMATIC TRANSAXLE

id051723802000

10 7

11

13
12

6
15

14
14 4 3

ac9uuw00002215

05-17–2
1890-1U-06H(05-17).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

1 Automatic transaxle fluid (ATF) 8 Automatic transaxle
(See 05-17-11 AUTOMATIC TRANSAXLE FLUID (See 05-17-30 AUTOMATIC TRANSAXLE
(ATF) INSPECTION [AW6A-EL, AW6AX-EL].) REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
(See 05-17-12 AUTOMATIC TRANSAXLE FLUID EL].)
(ATF) REPLACEMENT [AW6A-EL, AW6AX-EL].) 9 Oil seal (differential)
2 Transaxle fluid temperature (TFT) sensor (See 05-17-39 OIL SEAL (DIFFERENTIAL)
(See 05-17-13 TRANSAXLE FLUID REPLACEMENT [AW6A-EL, AW6AX-EL].)
TEMPERATURE (TFT) SENSOR INSPECTION 10 Differential gear O-ring
[AW6A-EL, AW6AX-EL].) (See 05-17-42 DIFFERENTIAL GEAR O-RING
(See 05-17-14 TRANSAXLE FLUID REPLACEMENT [AW6A-EL, AW6AX-EL].)
TEMPERATURE (TFT) SENSOR REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].) 11 Control valve body
(See 05-17-42 CONTROL VALVE BODY
3 Input/turbine speed sensor REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
(See 05-17-16 INPUT/TURBINE SPEED SENSOR EL].)
INSPECTION [AW6A-EL, AW6AX-EL].)
(See 05-17-18 INPUT/TURBINE SPEED SENSOR 12 Torque converter
REMOVAL/INSTALLATION [AW6A-EL, AW6AX- (See 05-17-50 TORQUE CONVERTER REMOVAL/
EL].) INSTALLATION [AW6A-EL, AW6AX-EL].)
4 Vehicle speed sensor 13 Oil seal (oil pump)
(See 05-17-50 OIL SEAL (OIL PUMP) 05-17
(See 05-17-18 VEHICLE SPEED SENSOR (VSS)
INSPECTION [AW6A-EL, AW6AX-EL].) REPLACEMENT [AW6A-EL, AW6AX-EL].)
(See 05-17-20 VEHICLE SPEED SENSOR (VSS) 14 Oil cooler
REMOVAL/INSTALLATION [AW6A-EL, AW6AX- (See 05-17-51 OIL COOLER FLUSHING [AW6A-
EL].) EL, AW6AX-EL].)
5 Solenoid valve (See 05-17-52 OIL COOLER REMOVAL/
(See 05-17-21 SOLENOID VALVE INSPECTION INSTALLATION [AW6A-EL, AW6AX-EL].)
[AW6A-EL, AW6AX-EL].) (See 05-17-55 OIL COOLER DISASSEMBLY/
ASSEMBLY [AW6A-EL, AW6AX-EL].)
6 TCM
(See 05-17-13 TRANSAXLE RANGE (TR) 15 Drive plate
SWITCH INSPECTION [AW6A-EL, AW6AX-EL].) (See 05-17-58 DRIVE PLATE REMOVAL/
(See 05-17-22 TCM INSPECTION [AW6A-EL, INSTALLATION [AW6A-EL, AW6AX-EL].)
AW6AX-EL].)
(See 05-17-26 TCM REMOVAL/INSTALLATION
[AW6A-EL, AW6AX-EL].)
7 Oil seal (manual shaft)
(See 05-17-30 OIL SEAL (MANUAL SHAFT)
REPLACEMENT [AW6A-EL, AW6AX-EL].)

End Of Sie
MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL]
id051723802100
Mechanical System Test Preparation
1. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
2. Inspect the engine coolant level. (See 01-12-3 COOLING SYSTEM SERVICE WARNINGS [MZI-3.5].) (See 01-
12-3 ENGINE COOLANT LEVEL INSPECTION [MZI-3.5].)
3. Inspect the engine oil level. (See 01-11-2 ENGINE OIL LEVEL INSPECTION [MZI-3.5].)
4. Inspect the ATF level. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5. Inspect the idle speed. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
6. Inspect the ignition timing. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)

05-17–3
1890-1U-06H(05-17).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Line Pressure Test
1. Perform mechanical system test preparation. (See05-17-3 Mechanical System Test Preparation.)

Warning
• Removing the test plug when the ATF is hot can be dangerous. Hot ATF can come out of the
opening and badly burn you. Before removing the test plug, allow the ATF to cool.

2. Connect the SSTs (49 HD64 406A and, 49 0378 400C) to the line pressure inspection port and replace the
gauge of the SST (49 0378 400C) with the SST (49 B019 901B).

D, M RANGE R POSITION

49 B019 901B 49 B019 901B 49 HD64 406A

49 HD64 406A

49 0378 400C

49 0378 400C

ac9uuw00001662

3. Start the engine and warm it up until the ATF reaches 60—70 °C {140—158 °F}.
4. Shift the selector lever to the D range.

Caution
• Perform the test at least 3 times and calculate the average.

5. Read the line pressure while the engine is idling for the D range.
6. Read the line pressure while the engine is idling for the R position and M range in the same manner as in Steps
4—5.

Line pressure
Position/range Line pressure (kPa {kgf/cm2, psi})
D, M Idle 350—410 {3.6—4.1, 51—59}
R Idle 580—670 {6.0—6.8, 85—97}

7. Stop the engine, then replace the SST (49 B019 901B) with the gauge of the SST (49 0378 400C).

05-17–4
1890-1U-06H(05-17).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

8. Connect the M-MDS to the DLC-2.
9. Measure the LPS PID value.
10. Start the engine.
11. Firmly depress the brake pedal with the left foot.
12. Shift the selector lever to the D range.

Caution
• If the accelerator pedal is pressed for
more than 5 s while the brake pedal is DLC-2
pressed, the transaxle could be
damaged. Therefore, perform Steps 14
and 15 within 5 s.
ac9uuw00001943

13. Gradually depress the accelerator pedal with the

right foot.
14. When the engine speed no longer increases, quickly read the line pressure and release the accelerator pedal.
15. Shift the selector lever to the N position and idle the engine for 1 min or more to cool the ATF.
16. Verify that the line pressure and LPS PID current values change according to the following graph by changing
the shift throttle opening angle when shifting to the D range and R position with the engine running. 05-17
— The line pressure standard other than when the engine is idling cannot be determined because the
maximum line pressure for this automatic transaxle is controlled by vehicle conditions.

R POSITION D RANGE LINE PRESSURE

2,000
{20.4, 290}
1,500 1,000
{15.3, 218}

LINE PRESSURE LINE PRESSURE

(kPa {kgf/cm2 ,psi}) CONTROL SOLENOID
CURRENT
(mA)

500
{5.1, 73} 300 CURRENT 300
{5.1, 73}

IDLE STALL
THROTTLE OPENING

ac9uuw00001944

Warning
• Removing the SST when the ATF is hot can be dangerous. Hot ATF can come out of the opening
and badly burn you. Before removing the SST, allow the ATF to cool.

17. Remove the SSTs.

18. Install a test plug in the inspection port.

Tightening torque
5.9—8.8 N·m {61—89 kgf·cm, 53—77 in·lbf}

Line pressure test evaluation

Condition Possible cause
• Line pressure control solenoid malfunction
Lower than specification in D range and • Primary regulator valve malfunction
R position • Oil pump malfunction
• Oil leaking from D range or R position hydraulic circuit
Constant pressure without fluctuation in
• Line pressure control solenoid malfunction
hydraulic pressure to throttle in D range
• Control valve body internal malfunction
and R position
Current to throttle does not change in D • TCM internal malfunction
range and R position • Connector malfunction
Hydraulic pressure in R position is not
• Primary regulator valve malfunction
higher than D range

05-17–5
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AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Stall Test
1. Perform mechanical system test preparation. (See 05-17-3 Mechanical System Test Preparation.)
2. Start the engine.
3. Firmly depress the brake pedal with the left foot.
4. Shift the selector lever to the D range.

Caution
• If the accelerator pedal is depressed for more than 5 s while the brake pedal is depressed, the
transaxle could be damaged. Therefore, perform Steps 5 and 6 within 5 s.
• Perform the test at least 3 times and calculate the average.

5. Gently depress the accelerator pedal with the right foot.

6. When the engine speed no longer increases, quickly read the engine speed and release the accelerator pedal.
7. Shift the selector lever to the N position and idle the engine for 1 min or more to cool the ATF.
8. Perform a stall test of the M range and R position in the same manner as in Steps 3—7.
9. Turn off the engine.

Engine stall speed

Position/range Engine stall speed (rpm)
D, M
2,435
R

Evaluation of stall test

Condition Possible cause
• Low line pressure (Line pressure control solenoid
malfunction, primary regulator valve malfunction)
• Control valve body component malfunction (shift solenoid
In D, M ranges
C hydraulic pressure system)
• C1 clutch slipping
• One-way clutch malfunction
• Low line pressure (Line pressure control solenoid
malfunction, primary regulator valve malfunction)
Above specification
• Control valve body component malfunction (shift solenoid
In R position
E hydraulic pressure system)
• C3 clutch malfunction (slipping)
• B2 brake malfunction (slipping)
• Low line pressure (Line pressure control solenoid
malfunction, primary regulator valve malfunction)
In all positions/ranges
• Oil pump malfunction
• Oil strainer clogging
• Engine lack of power
Below specification
• Torque converter one-way clutch slipping

Time Lag Test

1. Perform mechanical system test preparation. (See05-17-3 Mechanical System Test Preparation.)
2. Start the engine.
3. Warm up the engine until the ATF temperature reaches 60—70°C {140—158°F}.
4. Shift the selector lever from the N position to D range.
5. Use a stopwatch to measure the time it takes from shifting until shock is felt. Take three measurements for each
test and average from the results using the following formula.

Formula
Average time lag = (Time 1 + Time 2 + Time 3) / 3

6. Perform the test for the following shifts in the same manner as in Step 5.
• N position → R position

Average time lag

N position → D range: 1.5 s or less
N position → R position: 1.5 s or less

05-17–6
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AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Evaluation of time lag test
Condition Possible cause
• Control valve body malfunction (shift solenoid C hydraulic
pressure system)
• C1 clutch slipping
N→D shift More than specification
• One-way clutch malfunction
• Oil pump malfunction
• Oil strainer clogging
• Control valve body malfunction (shift solenoid E hydraulic
pressure system)
• C3 clutch slipping
N→R shift More than specification
• B2 brake slipping
• Oil pump malfunction
• Oil strainer clogging

End Of Sie
ROAD TEST [AW6A-EL, AW6AX-EL]
id051723802200

Warning 05-17
• When performing a road test, be aware of other vehicles, people, and other impediments in order
to avoid an accident.

Note
• When the legal speed limit must be exceeded, use a chassis dynamometer instead of performing a road
test.

Road Test Preparation

1. Inspect the engine coolant level. (See 01-12-3 COOLING SYSTEM SERVICE WARNINGS [MZI-3.5].) (See 01-
12-3 ENGINE COOLANT LEVEL INSPECTION [MZI-3.5].)
2. Inspect the engine oil level. (See 01-11-2 ENGINE OIL LEVEL INSPECTION [MZI-3.5].)
3. Inspect the ATF level. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
4. Inspect the idle speed. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
5. Inspect the ignition timing. (See 01-10-57 ENGINE TUNE-UP [MZI-3.5].)
6. Bring up the engine and transaxle to normal operating temperature.

05-17–7
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AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Shift Diagram
D range (normal mode)
2WD
TCC OPERATION AVAILABLE
8/8
3 4
4 5
7/8
2 3 3 4
2 3
6/8
1 2 1 2 5
4
THROTTLE OPENING

5/8

4/8

5 6 5 6
3/8

2/8

SHIFT UP
1/8
SHIFT DOWN

0/8
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230
{0} {6.2} {12} {19} {25} {31} {37} {43} {50} {56} {62} {68} {74} {81} {87} {93} {99} {105} {112} {118} {124} {131} {137} {143}

6GR TCC
6GR TCC VEHICLE SPEED km/h {mph}
OPERATION OFF
OPERATION ON
4GR TCC
OPERATION OFF
5GR TCC
5GR TCC OPERATION ON
OPERATION OFF 4GR TCC
OPERATION ON
ac9uuw00001663

05-17–8
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AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

AWD

TCC OPERATION AVAILABLE

8/8
3 4
4 5
7/8
2 3 3 4
2 3
6/8
1 2 1 2 5
4
THROTTLE OPENING

5/8

4/8

5 6 5 6
3/8

2/8
05-17
SHIFT UP
1/8
SHIFT DOWN

0/8
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230
{0} {6.2} {12} {19} {25} {31} {37} {43} {50} {56} {62} {68} {74} {81} {87} {93} {99} {105} {112} {118} {124} {131} {137} {143}
4GR TCC 5GR TCC
OPERATION OFF OPERATION ON VEHICLE SPEED km/h {mph}
6GR TCC 6GR TCC
OPERATION OFF OPERATION ON
5GR TCC
OPERATION OFF 4GR TCC
OPERATION ON
ac9uuw00002291

D Range Test
1. Perform road test preparation. (See05-17-7 Road Test Preparation.)
2. Shift the selector lever to D range.
3. Accelerate with the depressing amount of accelerator pedal half and then fully depress.
4. Verify that 1→2, 2→3, 3→4, 4→5, and 5→6 upshifts and downshifts are obtained. The shift points must be as
shown in the table below.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE [AW6A-EL, AW6AX-EL].)
5. Drive the vehicle in 6GR, 5GR, 4GR, 3GR, and 2GR and verify that kickdown occurs for 6→5, 5→4, 4→3,
3→2, 2→1 downshifts, and that the shift points are as shown in the table below.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE [AW6A-EL, AW6AX-EL].)
6. Drive the vehicle and verify that TCC operation is obtained. The operation points must be as shown in the table
below.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE [AW6A-EL, AW6AX-EL].)

05-17–9
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AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Vehicle speed at shift point table
Throttle Vehicle speed Turbine speed
Range Mode Shift
condition (km/h {mph}) (rpm)
D1→D2 49—55 {31—34} 5,250—5,850
D2→D3 95—103 {59—63} 5,800—6,250
Wide open D3→D4 145—155 {90—96} 5,800—6,150
throttle TCC ON (D4) 145—155 {90—96} 4,300—4,550
D4→D5 206—216 {128—133} 6,150—6,350
TCC ON (D5) 206—216 {128—133} 4,550—4,750
D1→D2 29—39 {18—24} 3,100—4,150
D2→D3 57—76 {36—47} 3,450—4,650
D3→D4 88—115 {55—71} 3,500—4,600
TCC ON (D4) 88—115 {55—71} 2,600—3,400
Half throttle
D4→D5 134—166 {84—102} 4,000—4,900
D NORMAL TCC ON (D5) 134—166 {84—102} 2,950—3,650
D5→D6 200—226 {124—140} 4,450—4,950
TCC ON (D6) 200—226 {124—140} 3,550—3,950
D6→D5 67—73 {42—45} 1,200—1,250
D5→D4 41—47 {26—29} 950—1,000
Closed throttle D4→D3 23—29 {15—17} 700—850
position
D3→D1 9—15 {6—9} 400—550
D2→D1 9—15 {6—9} 550—900
D5→D4 180—190 {112—117} 4,000—4,150
D4→D3 134—144 {84—89} 4,000—4,250
Kickdown
D3→D2 87—95 {54—58} 3,500—3,750
D2→D1 38—44 {24—27} 2,350—2,650
D1→D2 49—55 {31—34} 5,250—5,850
Wide open D2→D3 95—103 {59—63} 5,800—6,250
throttle D3→D4 145—155 {90—96} 5,800—6,150
D4→D5 206—216 {128—133} 6,150—6,350
D1→D2 29—39 {18—24} 3,100—4,150
D2→D3 57—76 {36—47} 3,450—4,650
Half throttle D3→D4 88—115 {55—71} 3,500—4,600
D4→D5 143—172 {89—106} 4,250—5,050
D5→D6 201—226 {125—140} 4,450—4,950
D AAS
D6→D5 107—113 {67—70} 1,900—1,950
D5→D4 65—71 {41—44} 1,450—1,550
Closed throttle D4→D3 27—33 {17—20} 800—950
position
D3→D1 9—15 {6—9} 400—550
D2→D1 9—15 {6—9} 550—900
D5→D4 180—190 {112—117} 4,000—4,150
D4→D3 134—144 {84—89} 4,000—4,250
Kickdown
D3→D2 87—95 {54—58} 3,500—3,750
D2→D1 38—44 {24—27} 2,350—2,650

05-17–10
1890-1U-06H(05-17).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

M Range Test
1. Perform road test preparation. (See05-17-7 Road Test Preparation.)
2. Shift the selector lever to M range.
3. Verify that 1→2, 2→3, 3→4, 4→5 and 5→6 upshifts and 6→5, 5→4, 4→3, 3→2, and 2→1 downshifts are
obtained by manual shifting of the selector lever forward and back.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE [AW6A-EL, AW6AX-EL].)
4. Decelerate the vehicle and verify that 6→5, 5→4, 4→3, 3→1 downshifts are obtained. The shift points must be
as shown in the table below.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE [AW6A-EL, AW6AX-EL].)
5. Decelerate the vehicle and verify that engine braking effect is felt in 1GR.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE [AW6A-EL, AW6AX-EL].)
6. Drive the vehicle and verify that TCC operation is obtained in 4GR, 5GR and 6GR. The operation points must
be as shown in the table below.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE [AW6A-EL, AW6AX-EL].)
7. Drive the vehicle in 6GR, 5GR, 4GR and 3GR and verify that kickdown occurs for 6→5, 5→4, 4→3, 3→2 05-17
downshifts, and that the shift points are as shown in the table below.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE [AW6A-EL, AW6AX-EL].)
Vehicle speed at shift point table
Throttle Vehicle speed Turbine speed
Range Mode Shift
condition km/h {mph} (rpm)
Half throttle TCC ON (M6) 201—216 {125—133} 3,550—3,800
M6→M5 44—50 {28—31} 800—850
M5→M4 34—40 {22—24} 750—850
All round M4→M3 23—29 {15—17} 700—850
M Manual M3→M1 6—12 {4—7} 400—700
M2→M1 6—12 {4—7} 250—450
M5→M4 85—95 {53—58} 1,900—2,050
Kickdown M4→M3 60—70 {38—43} 1,800—2,050
M3→M2 36—44 {23—27} 1,450—1,750

P Position Test
1. Shift into P position on a gentle slope. Release the brake and verify that the vehicle does not roll.
• If there is any malfunction, inspect the ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING ITEM TABLE
[AW6A-EL, AW6AX-EL].)
End Of Sie
AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [AW6A-EL, AW6AX-EL]
WM: AUTOMATIC TRANSMISSION/TRANSAXLE FLUID

id051723800500
Automatic Transaxle Fluid (ATF) Condition Inspection
1. Inspect the ATF for the following to determine whether the transaxle should be disassembled.
• The ATF is muddy.
• The ATF smells strange or unusual.
ATF Condition
Condition Possible cause
Clear dark red Normal —
• Damaged oil cooler
• Poor filler tube installation:
Light red (pink) Contaminated with water Problem could occur to parts inside the transaxle due
to water contamination.
If necessary, replace the transaxle.
Defective powertrain components inside the transaxle:
Particles cause wide range of problems by clogging
the oil pipe, control valve body and oil cooler.
Has burnt smell and metal
Reddish Deteriorated ATF • A large amount of metal particles are found.
particles are found
brown If necessary, replace the transaxle.
• Flush the system due to possible clogging of the oil
pipe or oil cooler.
Has no burnt smell Normal • Discoloration by oxidation

05-17–11
1890-1U-06H(05-17).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Automatic Transaxle Fluid (ATF) Level Inspection

Caution
• The ATF amount varies according to ATF temperature. Therefore, when checking the ATF level or
replacing the ATF, use a thermometer to measure the temperature and adjust the ATF amount to
the specified level according to the specified temperature.

1. Place the vehicle on level ground.

2. Apply the parking brake and position wheel chocks securely to prevent the vehicle from rolling.
3. Adjust the length or thermometer probe so that
the length is the same as the depth gauge, and
hold the probe with a paper holder. Insert into the
filler tube and measure the temperature.
• If necessary, inspect the ATF before warming
up the engine. In this case, use the ATF
temperature (15—25 °C {59—77 °F}).
4. Warm up the engine until the ATF reaches 60—70
°C {140—158 °F}.
5. Shift the selector lever and pause momentarily in
each range (P—D) while depressing the brake
pedal.
ac9uuw00001945
6. Shift the selector lever to P position.
7. Verify that the ATF level is in the HOT range (65
°C {149 °F}) while the engine is idling. ATF TEMPERATURE
60—70 ˚C {140—158 ˚F}
• If necessary, add ATF to the specification.
HOT RANGE
ATF type
JWS3309
20˚C 65˚C
End Of Sie
(REFERENCE)

ATF TEMPERATURE
15—25 ˚C {59—77 ˚F}

ac9uuw00001665

AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-EL]

id051723800600

Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.

1. Remove the oil dipstick.

2. Remove the oil drain plug and gasket.
3. Drain the ATF into a container.
4. Install a new gasket and the drain plug.

Tightening torque
23.5—54.9 N·m {2.4—5.5 kgf·m, 17.4—40.4
ft·lbf}

5. Add the specified ATF through the oil filler tube

until it reaches the lower notch of dipstick.

ATF
ac9uuw00001946
Type: JWS3309
Capacity (Approx. quantity): 7.0 L {7.4 US qt,
6.2 lmp qt}

6. Ensure that the ATF level is in the HOT range (65 °C {149 °F}).
• Add ATF to the specified level as necessary.
End Of Sie
WM: AUTOMATIC TRANSMISSION/TRANSAXLE INPUT (SENSOR/SWITCH)

05-17–12
1890-1U-06H(05-17).fm 13 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

TRANSAXLE RANGE (TR) SWITCH INSPECTION [AW6A-EL, AW6AX-EL]
id051723800900

Note
• TR switch function is installed as one part of TCM.

1. Inspect the TCM. (See 05-17-22 TCM INSPECTION [AW6A-EL, AW6AX-EL].)

End Of Sie
TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR INSPECTION [AW6A-EL, AW6AX-EL]
id051723801000
On-Vehicle Inspection

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].) 05-17
3. Remove the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
4. Verify that there is no continuity between coupler
component terminals B7 and GND, or B8 and
GND.
• If there is any malfunction, perform an off-
vehicle inspection of TFT sensor. (See 05-17- B4 B3 B2 B1
B11 B10 B9 B8 B7 B5
13 Off-Vehicle Inspection.)
B18 B17 B16 B14 B13 B12
5. Install the TCM. (See 05-17-26 TCM REMOVAL/ B22 B21 B20 B19
INSTALLATION [AW6A-EL, AW6AX-EL].)
6. Install the air cleaner component. (See 01-13-4
INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
7. Connect the negative battery cable.
ac9uuw00001947

Off-Vehicle Inspection

Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Drain the ATF. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-
EL].)
4. Remove the oil cooler.
5. Remove the oil pipe. (See 05-17-52 OIL COOLER OIL
REMOVAL/INSTALLATION [AW6A-EL, AW6AX- COOLER
EL].)
6. Remove the control valve body. (See 05-17-42
CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
7. Remove the TFT sensor. (See 05-17-14
TRANSAXLE FLUID TEMPERATURE (TFT)
SENSOR REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
OIL PIPE
ac9uuw00001948

05-17–13
1890-1U-06H(05-17).fm 14 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

8. Place the TFT sensor and a thermometer in ATF
as shown in the figure, and heat the ATF
gradually.
9. Measure the resistance between the coupler
component terminals B7and B8.
• If there is any malfunction, replace the TFT COUPLER
sensor. (See 05-17-14 TRANSAXLE FLUID COMPONENT
TEMPERATURE (TFT) SENSOR REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)

Transaxle fluid temperature (TFT) sensor

ATF temperature (°C {°F}) Resistance (kilohm)
10 {50} 5.62—7.31
B4 B3 B2 B1
25 {77} Approx. 3.5
B11 B10 B9 B8 B7 B5
110 {230} 0.22—0.27 B18 B17 B16 B14 B13 B12
B22 B21 B20 B19
10. Install the TFT sensor. (See 05-17-14
TRANSAXLE FLUID TEMPERATURE (TFT) ac9uuw00001949

SENSOR REMOVAL/INSTALLATION [AW6A-EL,

AW6AX-EL].)
11. Install the control valve body. (See 05-17-42 CONTROL VALVE BODY REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
12. Install the oil pipe. (See 05-17-52 OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
13. Install the oil cooler. (See 05-17-52 OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
14. Add ATF to the specified level. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT
[AW6A-EL, AW6AX-EL].)
15. Install the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
16. Connect the negative battery cable.
End Of Sie
TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]
id051723801100

Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Drain the ATF. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-
EL].)
4. Remove the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
5. Remove the oil cooler.
6. Remove the oil pipe. (See 05-17-52 OIL COOLER OIL
REMOVAL/INSTALLATION [AW6A-EL, AW6AX- COOLER
EL].)
7. Remove the control valve body. (See 05-17-42
CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)

OIL PIPE
ac9uuw00001950

05-17–14
1890-1U-06H(05-17).fm 15 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

8. Remove the coupler component lock plate.

Caution
• Do not damage the wiring harness.
• Do not pull hard on the wiring harness.

9. Remove the coupler component from the

transaxle case.

ac9uuw00001951

10. Remove the O-ring and the gasket from the

coupler component.
11. Apply ATF to a new gasket and install it on the
coupler component.
O-RING
Caution 05-17
• Do not apply ATF to the O-ring.
GASKET

ac9uuw00001952

12. Install a new O-ring to the coupler component.

Caution
• Do not apply too much force to the
coupler component. O-RING
• Do not damage the coupler component.

13. Install the coupler component to the transaxle GASKET

case.

ac9uuw00001952

14. Install a new coupler component lock plate.

15. Install the control valve body. (See 05-17-42
CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
16. Install the oil pipe. (See 05-17-52 OIL COOLER
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)
17. Install the oil cooler. (See 05-17-52 OIL COOLER
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)
18. Install the TCM. (See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
ac9uuw00001953
19. Add ATF to the specified level. (See 05-17-12
AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT [AW6A-EL, AW6AX-EL].)
20. Install the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
21. Connect the negative battery cable.
22. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
End Of Sie

05-17–15
1890-1U-06H(05-17).fm 16 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

INPUT/TURBINE SPEED SENSOR INSPECTION [AW6A-EL, AW6AX-EL]
id051723801200
On-Vehicle Inspection

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Remove the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
4. Verify that there is no continuity between the
coupler component terminals B12 and GND or
B13 and GND.
• If there is any malfunction, inspect the coupler
component. B4 B3 B2 B1

• If the coupler component is normal, perform B11 B10 B9 B8 B7 B5

B18 B17 B16 B14 B13 B12
an off-vehicle inspection of input/turbine B22 B21 B20 B19
speed sensor. (See05-17-16 Off-Vehicle
Inspection.)

Note
• Inspect with a tester that can indicate more
ac9uuw00001954
than 10 megohms and confirm that the
value is more than 1 megohm.

5. Verify that there is continuity between coupler

component terminals B12 and B13.
• If there is any malfunction, inspect the coupler
component.
• If the coupler component is normal, replace B4 B3 B2 B1
B11 B10 B9 B8 B7 B5
the input/turbine speed sensor. (See 05-17-18
B18 B17 B16 B14 B13 B12
INPUT/TURBINE SPEED SENSOR B22 B21 B20 B19
REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
6. Install the TCM. (See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
7. Install the air cleaner component. (See 01-13-4
ac9uuw00001954
INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
8. Connect the negative battery cable.

Off-Vehicle Inspection

Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Drain the ATF. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-
EL].)

05-17–16
1890-1U-06H(05-17).fm 17 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

4. Remove the oil cooler.
5. Remove the oil pipe. (See 05-17-52 OIL COOLER OIL
REMOVAL/INSTALLATION [AW6A-EL, AW6AX- COOLER
EL].)
6. Remove the control valve body. (See 05-17-42
CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
7. Remove the input/turbine speed sensor. (See 05-
17-18 INPUT/TURBINE SPEED SENSOR
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)
OIL PIPE
ac9uuw00001955

8. Connect the input/turbine speed sensor terminal

2 to the battery positive terminal, connect the
battery negative terminal to input/turbine speed
sensor terminal 1 through an ammeter set to a
resistance of 100 ohm. 100 ohm
05-17

1 2

ac9uuw00001956

9. Measure the current while waving a magnet back

and forth over the top of the input/turbine speed
sensor (less than 5 mm {0.197 in}).
• If there is any malfunction, replace the input/
turbine speed sensor. (See 05-17-18 INPUT/ WAVE BACK AND FORTH
TURBINE SPEED SENSOR REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)

Input/turbine speed sensor LESS THAN 5 mm {0.197 in}

Signal Current (mA)
MAGNET
High 12.0—16.0
Low 4.0—8.0

10. Install the input/turbine speed sensor. (See 05-

17-18 INPUT/TURBINE SPEED SENSOR
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].) SHAKING DIRECTION
11. Install the control valve body. (See 05-17-42 ac9uuw00001957
CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
12. Install the oil pipe. (See 05-17-52 OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
13. Install the oil cooler. (See 05-17-52 OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
14. Add ATF to the specified level. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT
[AW6A-EL, AW6AX-EL].)
15. Install the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
16. Connect the negative battery cable.
17. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
End Of Sie

05-17–17
1890-1U-06H(05-17).fm 18 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]
id051723801300

Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until then are cool
before replacing the ATF.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Drain the ATF. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-
EL].)
4. Remove the oil cooler.
5. Remove the oil pipe. (See 05-17-52 OIL COOLER OIL
REMOVAL/INSTALLATION [AW6A-EL, AW6AX- COOLER
EL].)
6. Remove the control valve body. (See 05-17-42
CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)

Caution
• Do not damage the input/turbine speed
sensor.
OIL PIPE
ac9uuw00001958

7. Remove the input/turbine speed sensor.

8. Install the input/turbine speed sensor.

Tightening torque
3.9—6.9 N·m {40—70 kgf·cm, 26—60 in·lbf}

9. Install the control valve body. (See 05-17-42

CONTROL VALVE BODY REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
10. Install the oil pipe. (See 05-17-52 OIL COOLER
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)
ac9uuw00001959
11. Install the oil cooler. (See 05-17-52 OIL COOLER
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)
12. Add ATF to the specified level. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT
[AW6A-EL, AW6AX-EL].)
13. Install the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
14. Connect the negative battery cable.
15. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
End Of Sie
VEHICLE SPEED SENSOR (VSS) INSPECTION [AW6A-EL, AW6AX-EL]
id051723801400
On-Vehicle Inspection

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Remove the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)

05-17–18
1890-1U-06H(05-17).fm 19 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

4. Verify that there is no continuity between the
coupler component terminals B19 and GND or
B20 and GND.
• If there is any malfunction, inspect the coupler
component. B4 B3 B2 B1

• If the coupler component is normal, replace B11 B10 B9 B8 B7 B5

B18 B17 B16 B14 B13 B12
the ATX. (See 05-17-30 AUTOMATIC B22 B21 B20 B19
TRANSAXLE REMOVAL/INSTALLATION
[AW6A-EL, AW6AX-EL].)

Note
• Inspect with a tester that can indicate more
ac9uuw00001960
than 10 megohms and confirm that the
value is more than 1 megohm.

5. Verify that there is continuity between coupler

component terminals B19 and B20.
• If there is any malfunction, inspect the coupler
component. 05-17
• If the coupler component is normal, replace B4 B3 B2 B1
B11 B10 B9 B8 B7 B5
the ATX. (See 05-17-30 AUTOMATIC
B18 B17 B16 B14 B13 B12
TRANSAXLE REMOVAL/INSTALLATION B22 B21 B20 B19
[AW6A-EL, AW6AX-EL].)
6. Install the TCM. (See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
7. Install the air cleaner component. (See 01-13-4
INTAKE-AIR SYSTEM REMOVAL/
ac9uuw00001960
INSTALLATION [MZI-3.5].)
8. Connect the negative battery cable.

Off-Vehicle Inspection

Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.

1. Disconnect the negative battery cable.

2. Remove the VSS. (See 05-17-20 VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
3. Connect the VSS terminal 2 to the battery positive
terminal, connect the battery negative terminal to
VSS terminal 1 through an ammeter set to a
resistance of 100 ohm.
100 ohm

1 2

ac9uuw00001961

05-17–19
1890-1U-06H(05-17).fm 20 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

4. Measure the current while waving a magnet back
and forth over the top of the VSS (less than 5
mm {0.197 in}).
• If there is any malfunction, replace the VSS.
(See 05-17-20 VEHICLE SPEED SENSOR WAVE BACK AND FORTH
(VSS) REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)

LESS THAN 5 mm {0.197 in}

MAGNET

SHAKING DIRECTION
ac9uuw00001962

VSS
Signal Current (mA)
High 12.0—16.0
Low 4.0—8.0

5. Install the VSS. (See 05-17-20 VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
6. Connect the negative battery cable.
7. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
End Of Sie
VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]
id051723806100

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to drop water or foreign material on the connector when disconnecting it.
• If foreign materials are stuck to the VSS, disturbance by magnetic flux can cause sensor output to
be abnormal and thereby negatively affect control. Make sure that foreign materials such as iron
filings are not stuck to the VSS during installation.

1. Remove the automatic transaxle. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION

[AW6A-EL, AW6AX-EL].)
2. Remove the VSS. (See Automatic Transaxle and Transfer Workshop Manual AW6A-EL, AW6AX-EL)
End Of Sie
WM: TRANSMISSION/TRANSAXLE OUTPUT (SOLENOID/INDICATOR LIGHT)

05-17–20
1890-1U-06H(05-17).fm 21 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

SOLENOID VALVE INSPECTION [AW6A-EL, AW6AX-EL]
id051723801900
Resistance Inspection (On-Vehicle Inspection)

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Remove the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
4. Measure the resistance between the following
terminals.
• If there is any malfunction, inspect the coupler
component.
• If the coupler component is normal, replace B4 B3 B2 B1
B11 B10 B9 B8 B7 B5 05-17
the control valve body. (See 05-17-42
B18 B17 B16 B14 B13 B12
CONTROL VALVE BODY REMOVAL/ B22 B21 B20 B19
INSTALLATION [AW6A-EL, AW6AX-EL].)

ac9uuw00001963

Solenoid valve resistance (ATF temperature: 20 °C {68 °F})

Terminal Solenoid valve Resistance (ohm)
B5—GND Shift solenoid A 11—15
B2—GND Shift solenoid B 11—15
B11—B10 Shift solenoid C 5.0—5.6
B17—B18 Shift solenoid D 5.0—5.6
B14—B22 Shift solenoid E 5.0—5.6
B21—B16 Shift solenoid F 5.0—5.6
B9—B4 TCC control solenoid 5.0—5.6
B3—B1 Line pressure control solenoid 5.0—5.6

5. Install the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)

6. Install the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
7. Connect the negative battery cable.

Continuity Inspection (On-Vehicle Inspection)

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Remove the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
4. Verify that there is no continuity between coupler component terminals B1, B3, B4, B9, B10, B11, B14, B17,
B18, B21, B22 and GND.
• If there is any malfunction, inspect the coupler component.
• If the coupler component is normal, replace the control valve body. (See 05-17-42 CONTROL VALVE
BODY REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
5. Install the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
6. Install the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
7. Connect the negative battery cable.
End Of Sie
WM: TCM

05-17–21
1890-1U-06H(05-17).fm 22 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

TCM INSPECTION [AW6A-EL, AW6AX-EL]
id051723800300
TR Switch Operating Inspection
1. Verify that the starter operates only when the ignition switch is turned to the START position with the selector
lever in P or N position.
• If there is any malfunction, neutral position learning. (See 05-17-26 TCM REMOVAL/INSTALLATION
[AW6A-EL, AW6AX-EL].)
2. Verify that the back-up lights illuminate when shifted to R position with the ignition switch at the ON position.
• If there is any malfunction, neutral position learning. (See 05-17-26 TCM REMOVAL/INSTALLATION
[AW6A-EL, AW6AX-EL].)
3. Verify that the positions of the selector lever and
the indicator light correspond. SELECTOR INDICATOR
• If there is any malfunction, perform the neutral LIGHT
position learning. (See 05-17-26 TCM
REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
4. Verify that the TR PID is normal.
• If there is any malfunction, perform the neutral
position learning. (See 05-17-26 TCM
REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
ac9uuw00001964

Control Module Inspection

1. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
2. Measure the voltage at each TCM connector (wiring harness-side) terminal and refer to the terminal voltage
table.
• If the voltage is not as specified in the Terminal Voltage Table (Reference), inspect the parts under
“Inspection item (s)”.

Warning
• Be careful not to damage the connector waterproofing when measuring the TCM terminal voltage.
If damaged, the waterproofing efficiency could be negatively affected.

Note
• Use the ground of terminal A9 of the TCM connector (wiring harness-side) when measuring terminal
voltage, as an error may occur when connecting the negative circuit tester to ground.

Terminal Voltage Table (Reference)

TCM SHORT CORD CONNECTOR (TCM SIDE)

A2 A1
A8 A7 A6 A5 A4 A3

A16 A15 A14 A13 A12 A11

A10 A9

ac9uuw00001965

Terminal Signal Connected to Test condition Voltage (V) Inspection item (s)
Battery back up • Inspect battery
A1 Battery Constant B+
supply • Inspect related harness
Shift up • Inspect selector lever
Below 1.0
(M range) component
Up switch Up switch
(See 05-18-7 SELECTOR
A3 (Selector lever (Selector lever
Other ranges, all LEVER COMPONENT
component) component) B+
positions INSPECTION)
• Inspect related harness

05-17–22
1890-1U-06H(05-17).fm 23 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Terminal Signal Connected to Test condition Voltage (V) Inspection item (s)
Shift down • Inspect selector lever
Below 1.0
(M range) component
Down switch Down switch
(See 05-18-7 SELECTOR
A4 (Selector lever (Selector lever
Other ranges, all LEVER COMPONENT
component) component) B+
positions INSPECTION)
• Inspect related harness
Ignition
Shift the switch B+
selector
Starter lock output ON • Inspect PCM
A5 PCM lever to
signal Ignition • Inspect related harness
P or N
position. switch Below 1.0
OFF
Because this
terminal is for serial
communication,
good/no good
A6 CAN_L PCM judgment by — • Inspect related harness
terminal voltage is 05-17
not possible. Carry
out inspection
according to DTCs.
M range Below 1.0 • Inspect selector lever
component
(See 05-18-7 SELECTOR
A7 M range switch M range switch Other positions, all
B+ LEVER COMPONENT
ranges INSPECTION)
• Inspect related harness
Ignition switch ON B+ • Inspect Ignition switch
A11 Power supply Ignition switch
Ignition switch OFF Below 1.0 • Inspect related harness
Shift the
selector • Inspect back-up light relay
Ignition lever to Below 1.0 (See 09-21-6 RELAY
A13 Back-up light relay Back-up light relay switch R INSPECTION)
ON position. • Inspect related harness
Other B+
Because this
terminal is for serial
communication,
good/no good
A14 CAN_H PCM judgment by — • Inspect related harness
terminal voltage is
not possible. Carry
out inspection
according to DTCs.

3. Remove the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)

4. Verify that continuity or resistance at terminal is as indicated in the terminal continuity/resistance table.
• If there is any malfunction, inspect the parts under “Inspection item (s)”.
— If the system does not work properly even though the parts or related wiring harnesses do not have any
malfunction, replace the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)

05-17–23
1890-1U-06H(05-17).fm 24 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Terminal Continuity/Resistance Table (Reference)

COUPLE COMPONENT

TCM SHORT CORD CONNECTOR (TCM SIDE)

B22 B21 B20 B19

A2 A1 B18 B17 B16 B14 B13 B12

A8 A7 A6 A5 A4 A3
B11 B10 B9 B8 B7 B5
A16 A15 A14 A13 A12 A11
A10 A9
B4 B3 B2 B1

ac9uuw00001966

Continuity/
Terminal Signal Connected to Test Condition Inspection item (s)
Resistance
A9 System GND GND Constant Continuity • Inspect related harness
• Inspect • Inspect line pressure
resistance control solenoid
Line pressure
Line pressure between couple ATF (See 05-17-21
control 5.0—5.6
B1 control component temperature: SOLENOID VALVE
solenoid (ohms)
solenoid terminals B3 20°C {68°F} INSPECTION [AW6A-
control GND
and B1 (wiring EL, AW6AX-EL])
harness-side). • Inspect related harness
• Inspect shift solenoid B
(See 05-17-21
Shift solenoid Shift solenoid 11—15 SOLENOID VALVE
B2 ATF temperature: 20°C {68°F}
B control B (ohms) INSPECTION [AW6A-
EL, AW6AX-EL])
• Inspect related harness
• Inspect • Inspect line pressure
resistance control solenoid
Line pressure
Line pressure between couple ATF (See 05-17-21
control 5.0—5.6
B3 control component temperature: SOLENOID VALVE
solenoid (ohms)
solenoid terminals B3 20°C {68°F} INSPECTION [AW6A-
control
and B1 (wiring EL, AW6AX-EL])
harness-side). • Inspect related harness
• Inspect • Inspect TCC control
resistance solenoid
TCC control between couple ATF (See 05-17-21
TCC control 5.0—5.6
B4 solenoid component temperature: SOLENOID VALVE
solenoid (ohms)
control GND terminals B9 20°C {68°F} INSPECTION [AW6A-
and B4 (wiring EL, AW6AX-EL])
harness-side). • Inspect related harness
• Inspect shift solenoid A
(See 05-17-21
Shift solenoid Shift solenoid 11—15 SOLENOID VALVE
B5 ATF temperature: 20°C {68°F}
A control A (ohms) INSPECTION [AW6A-
EL, AW6AX-EL])
• Inspect related harness
ATF
5.62—7.31
• Inspect temperature: • Inspect TFT sensor
(kilohms)
TFT sensor resistance 10°C {50°F} (See 05-17-13
B7
GND between couple ATF TRANSAXLE FLUID
Approx. 3.5
TFT sensor component temperature: TEMPERATURE (TFT)
(kilohms)
terminals B7 25°C {77°F} SENSOR INSPECTION
and B8 (wiring ATF [AW6A-EL, AW6AX-EL])
B8 TFT sensor harness-side). temperature:
0.22—0.27 • Inspect related harness
(kilohms)
110°C {230°F}

05-17–24
1890-1U-06H(05-17).fm 25 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Continuity/
Terminal Signal Connected to Test Condition Inspection item (s)
Resistance
• Inspect • Inspect TCC control
resistance solenoid
TCC control between couple ATF (See 05-17-21
TCC control 5.0—5.6
B9 solenoid component temperature: SOLENOID VALVE
solenoid (ohms)
control terminals B9 20°C {68°F} INSPECTION [AW6A-
and B4 (wiring EL, AW6AX-EL])
harness-side). • Inspect related harness
Shift solenoid • Inspect
B10 • Inspect shift solenoid C
C control GND resistance
(See 05-17-21
between couple ATF
Shift solenoid 5.0—5.6 SOLENOID VALVE
component temperature:
Shift solenoid C (ohms) INSPECTION [AW6A-
B11 terminals B11 20°C {68°F}
C control EL, AW6AX-EL])
and B10 (wiring
• Inspect related harness
harness-side).
Input/turbine • Inspect input/turbine
B12 speed sensor speed sensor
(–) • Inspect for continuity between (See 05-17-16 INPUT/ 05-17
Input/turbine
couple component terminals B12 Continuity TURBINE SPEED
Input/turbine speed sensor
and B13 (wiring harness-side). SENSOR INSPECTION
B13 speed sensor [AW6A-EL, AW6AX-EL])
(+) • Inspect related harness
• Inspect
resistance • Inspect shift solenoid E
between couple (See 05-17-21
ATF
Shift solenoid Shift solenoid component 5.0—5.6 SOLENOID VALVE
B14 temperature:
E control E terminals (ohms) INSPECTION [AW6A-
20°C {68°F}
B14and B22 EL, AW6AX-EL])
(wiring harness- • Inspect related harness
side).
• Inspect
resistance • Inspect shift solenoid F
between couple (See 05-17-21
ATF
Shift solenoid Shift solenoid component 5.0—5.6 SOLENOID VALVE
B16 temperature:
F control GND F terminals (ohms) INSPECTION [AW6A-
20°C {68°F}
B21and B16 EL, AW6AX-EL])
(wiring harness- • Inspect related harness
side).
Shift solenoid • Inspect
B17
D control resistance • Inspect shift solenoid D
between couple (See 05-17-21
ATF
Shift solenoid component 5.0—5.6 SOLENOID VALVE
temperature:
Shift solenoid D terminals (ohms) INSPECTION [AW6A-
B18 20°C {68°F}
D control GND B17and B18 EL, AW6AX-EL])
(wiring harness- • Inspect related harness
side).
Vehicle speed • Inspect VSS
B19 VSS
(–) (See 05-17-18
• Inspect for continuity between VEHICLE SPEED
couple component terminals B19 Continuity SENSOR (VSS)
Vehicle speed and B20 (wiring harness-side). INSPECTION [AW6A-
B20 VSS
(+) EL, AW6AX-EL])
• Inspect related harness
• Inspect
resistance • Inspect shift solenoid F
between couple (See 05-17-21
ATF
Shift solenoid Shift solenoid component 5.0—5.6 SOLENOID VALVE
B21 temperature:
F control F terminals (ohms) INSPECTION [AW6A-
20°C {68°F}
B21and B16 EL, AW6AX-EL])
(wiring harness- • Inspect related harness
side).

05-17–25
1890-1U-06H(05-17).fm 26 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Continuity/
Terminal Signal Connected to Test Condition Inspection item (s)
Resistance
• Inspect
resistance • Inspect shift solenoid E
between couple (See 05-17-21
ATF
Shift solenoid Shift solenoid component 5.0—5.6 SOLENOID VALVE
B22 temperature:
E control GND E terminals (ohms) INSPECTION [AW6A-
20°C {68°F}
B14and B22 EL, AW6AX-EL])
(wiring harness- • Inspect related harness
side).

End Of Sie
TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]
id051723800400

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Disconnect the TCM connector.
4. Remove the clip and disconnect the selector
cable.

Caution
• Do not use an impact wrench. Hold the TCM SELECTOR
manual shaft lever when removing the CABLE
manual shaft nut, or the transaxle may be
damaged.
MANUAL
SHAFT
LEVER

ac9uuw00001967

5. Set the adjustable wrench as shown in the figure

to hold the manual shaft lever.

MANUAL SHAFT LEVER ADJUSTABLE WRENCH

ac9uuw00001968

6. Remove the manual shaft nut and washer.

MANUAL
SHAFT NUT

WASHER

MANUAL
SHAFT
LEVER

TCM

ac9uuw00001969

05-17–26
1890-1U-06H(05-17).fm 27 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

7. Remove the TCM. TCM
MOUNTING
BOLT

TCM

ac9uuw00001970

Caution
• Do not touch the terminals.

05-17

ac9uuw00001971

8. Inspect the condition of the connector pin of the

coupler component (foreign material, bent pins,
broken pins) and O-ring after the TCM is
removed.

ac9uuw00001972

9. Align the transaxle case and coupler component

connector.

ac9uuw00001973

05-17–27
1890-1U-06H(05-17).fm 28 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

10. Be sure to match the position of the TCM
marking.

Caution
• Do not turn more than 60° from the
marking.

11. Install the TCM.

ac9uuw00001974

12. Verify the correct positioning of the TCM and

coupler component.
13. Tighten the TCM mounting bolts.

Tightening torque
19.6—29.4 N·m {2.0—2.9 kgf·m, 14.5—21.6
ft·lbf}

Caution
• Do not use an impact wrench. Hold the
manual shaft lever when removing the
manual shaft nut, or the transaxle may be
ac9uuw00001975
damaged.

14. Install the manual shaft lever and the washer.

MANUAL
SHAFT NUT

WASHER

MANUAL
SHAFT
LEVER

TCM

ac9uuw00001969

15. Set the adjustable wrench as shown in the figure

to hold the manual shaft lever, and tighten the
manual shaft nut.

Tightening torque
9.8—14.7 N·m {100—142 kgf·cm, 87—123
in·lbf}

MANUAL SHAFT LEVER ADJUSTABLE WRENCH

ac9uuw00001968

05-17–28
1890-1U-06H(05-17).fm 29 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

16. Install the clip to the selector cable as shown in
the figure.
17. Shift the selector lever to P position.
18. Turn the manual shaft lever to P position.

CLIP

ac9uuw00001976

19. Connect the selector cable and install the clip.

20. Connect the TCM connector.
21. Install the air cleaner component. (See 01-13-4
INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].) TCM SELECTOR
22. Connect the negative battery cable. CABLE
05-17

Warning
• If you replace the ATX or TCM, be sure to MANUAL
SHAFT
initialize the learned values and perform
LEVER
neutral position learning.
ac9uuw00001967
23. Perform the neutral position learning. (See 05-17-
29 Neutral Position Learning.)

Neutral Position Learning

1. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
2. Connect the M-MDS to the DLC-2.
3. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select "Toolbox" tab.
2. Select "Power train".
3. Select "Transmission".
• When using the PDS (Pocket PC)
1. Select "All Tests and Calibrations". DLC-2
4. Then, select the “Transmission Learning”.
5. Perform the N range learning according to the
directions on the screen.
• When “Operation Successful” is displayed,
ac9uuw00001977

shift the selector lever to the P position and

turn the ignition switch to the LOCK position, then to the ON position after 5 s.
• If “Reinstall TCM properly and then try again” is displayed, perform the following inspection:
— Verify that the transaxle manual shaft is in the N position.
• If the manual shaft is in a position other than N, shaft it to the N position.
— Verify that the selector cable is adjusted properly.
• If the selector cable is not adjusted properly, adjust it. (See 05-18-7 SELECTOR CABLE
ADJUSTMENT.)
— Inspect the manual shaft lever for deformation.
• If there is any malfunction, replace the manual shaft lever.
6. Shift the selector lever from P position to D range, then verify that the positions of the selector lever and the
indicator are aligned.
• If there is any malfunction, inspect the DTC. (See 05-02-5 DTC TABLE [AW6A-EL, AW6AX-EL].)
End Of Sie
WM: AUTOMATIC TRANSAXLE

05-17–29
1890-1U-06H(05-17).fm 30 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

OIL SEAL (MANUAL SHAFT) REPLACEMENT [AW6A-EL, AW6AX-EL]
id051723802300

Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Remove the TCM. (See 05-17-26 TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)

Caution
• Do not damage the transaxle case.
• Do not damage the manual shaft.

4. Remove and discard the oil seal using a tape-

wrapped flathead screwdriver.

Caution
• Do not damage the oil seal.

ac9uuw00001978
5. Using the SST and a hammer, tap a new oil seal
so that the specified oil seal position is obtained. 49 G030 797
Substitution SST
• 49 F026 102
Outer diameter: 27 mm {1.06 in} or more -0.3—0.4 mm
Inner diameter: 15—18 mm {0.60—0.70 in} {-0.0118—0.0157 in}
6. Install the TCM. (See 05-17-26 TCM REMOVAL/ 49 F026 102
INSTALLATION [AW6A-EL, AW6AX-EL].)
7. Install the air cleaner component. (See 01-13-4
INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
8. Connect the negative battery cable.
ac9uuw00001979
End Of Sie
AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]
id051723802400
1. Disconnect the negative battery cable.
2. Remove the following parts.
(1) Battery and battery tray (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
(2) Air cleaner component (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
(3) Engine cover
(4) Windshield wiper arm and blade (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/
INSTALLATION.)
(5) Cowl grille (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
(6) Cowl panel (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
(7) Front wheel
(8) Splash shield
(9) Side cover
(10)Propeller shaft (transfer side) (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Drain the ATF. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-
EL].)

Warning
• Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.

Caution
• To prevent the torque converter and transaxle from separating, remove the transaxle without
tilting it toward the torque converter.

05-17–30
1890-1U-06H(05-17).fm 31 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

4. Remove in the order shown in the figure.
5. Install in the reverse order of removal.
6. Add ATF to the specified level. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT
[AW6A-EL, AW6AX-EL].)
7. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
Test item
Service item
Line pressure test Stall test Time lag test Time lag test
ATX replacement X
ATX overhaul X X X X
Torque converter
X X
replacement
Oil pump replacement X
Control valve body
X
component
Clutch system
X X X
replacement
05-17
X : Test to be performed after the service work

05-17–31
1890-1U-06H(05-17).fm 32 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

AWD 42—62
{4.3—6.3,
31—45} 27 {2.8, 20}
21
40.5—54.7
16 {4.13—5.57,
29.9—40.3}

7.8—10.8 N·m
{80—110 kgf·cm,
42—62 15 19 70—95 in·lbf}
{4.3—6.3, 37—52 25 66.6—93.1
31—45} {3.8—5.3, {6.80—9.49,
37—52
1 28—38}
{3.8—5.3, 49.2—68.6}

42—62
5 28—38}
{4.3—6.3, 5
31—45} D R SST
2 R 22
4 A
7.8—10.8 N·m
{80—110 kgf·cm, A
14 70—95 in·lbf} D
E
74.5—104.9
15 D {7.60—10.69,
2WD 55.0—77.3}
24
16 7.8—10.8 N·m
7.8—10.8 N·m {80—110 kgf·cm,
{80—110 kgf·cm, R 70—95 in·lbf}
R E
70—95 in·lbf}
17
3
23 37—52 7.8—10.8 N·m
93.1—116.6 {3.8—5.3, 20
28—38} {80—110 kgf·cm,
{9.50—11.8, D 70—95 in·lbf}
68.7—85.9}
10
93.1—116.6 C
{9.50—11.8,
68.7—85.9}
B 14
18
18.6—25.5
{1.90—2.60,
47.0—59.0
13.8—18.8}
{4.80—6.01,
8 34.7—43.5}
43.1—52.6 6 12
{4.40—5.36,
31.8—38.7}
12
7 18.6—26.5 119.6—154.8
{1.9—2.7, {12.20—15.78,
9 14—19} 88.3—114.1}

43.1—52.6
{4.40—5.36,
31.8—38.7}
11
93.1—131.3 119.6—154.8
B R
{9.50—13.38, {12.20—15.78,
68.7—96.8} 88.3—114.1}
C
47.0—59.0
7 {4.80—6.01, 93.1—131.3
13 34.7—43.5} {9.50—13.38,
A 68.7—96.8}
8
43.1—52.6 9
{4.40—5.36, 43.1—58.8
31.8—38.7} {4.40—5.99,
31.8—43.3}
119.6—154.8 119.6—154.8
119.6—154.8
{12.20—15.78, {12.20—15.78,
{12.20—15.78, N·m {kgf·m, ft·lbf}
88.3—114.1} 88.3—114.1}
88.3—114.1}

ac9uuw00002245

05-17–32
1890-1U-06H(05-17).fm 33 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

1 TCM connector 15 Joint shaft
2 Ground (See 03-13-4 JOINT SHAFT REMOVAL/
INSTALLATION [2WD].)
3 Wiring harness bracket
16 Transfer bracket (AWD)
4 Selector cable
(See05-17-39 Selector Cable Installation Note.) 17 Oil hose
(See 05-17-52 OIL COOLER REMOVAL/
5 Transaxle mounting bolt (Upper side) INSTALLATION [AW6A-EL, AW6AX-EL].)
6 Steering shaft 18 Oil cooler
(See 06-14-6 STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION.) 19 Starter
(See 01-19-2 STARTER REMOVAL/INSTALLATION
7 Stabilizer control link [MZI-3.5].)
8 Tie-rod end ball joint 20 Heater pipe
(See 02-13-11 FRONT CROSSMEMBER
REMOVAL/INSTALLATION.) 21 Torque converter installation nuts
(See05-17-34 Torque Converter Nuts Removal
9 Lower arm ball joint Note.)
(See 02-13-8 FRONT LOWER ARM REMOVAL/ (See05-17-38 Torque Converter Nuts Installation
INSTALLATION.) Note.)
10 No.1 engine mount bracket 22 No.4 engine mount bracket
(See05-17-34 No.1 Engine Mount Removal Note.) 05-17
(See05-17-35 No.4 Engine Mount Bracket Removal
(See05-17-37 No.1 Engine Mount Installation Note.) Note.)
11 Transverse member (See05-17-37 No.4 Engine Mount Bracket
(See 02-13-15 TRANSVERSE MEMBER Installation Note.)
REMOVAL/INSTALLATION.) 23 Transaxle mounting bolt (lower side)
12 Crossmember bracket 24 Transaxle (2WD)
13 Crossmember (See05-17-36 Transaxle Removal Note.)
(See 02-13-11 FRONT CROSSMEMBER (See05-17-36 Transaxle Installation Note.)
REMOVAL/INSTALLATION.) 25 Oil filter tube, Dipstick, breather hose
14 Drive shaft
(See 03-13-14 FRONT DRIVE SHAFT REMOVAL/
INSTALLATION.)

AWD

90—100
{9.2—10.1,
66.4—73.7}

90—100
{9.2—10.1,
66.4—73.7}

25

24

N·m {kgf·m, ft·lbf}

ac9uuw00001667

24 Transfer (AWD) 25 Transaxle

05-17–33
1890-1U-06H(05-17).fm 34 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Torque Converter Nuts Removal Note
1. Remove the cover as shown in the figure.
2. Align the holes by turning the torque converter.

COVER

FASTENER

ac9uuw00001612

3. Insert a flathead screwdriver through the

converter housing service hole, and lock the drive
plate.

ac9uuw00001656

4. Remove the torque converter nuts.

NUT

ac9uuw00001668

No.1 Engine Mount Removal Note

1. Remove the No.1 engine mount bracket bolts A
and B as shown.

A
FRONT

ac9uuw00000966

05-17–34
1890-1U-06H(05-17).fm 35 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

2. Remove the No.1 engine mount, No.1 engine
mount bracket and the front crossmember as a
single unit. (See 02-13-11 FRONT
CROSSMEMBER REMOVAL/INSTALLATION.)

NO.1 ENGINE
MOUNT
ac9uuw00002246

No.4 Engine Mount Bracket Removal Note

1. Install the SST using the following procedure.

Caution
• Refer to the SST instruction manual for the basic handing procedure. 05-17

Note
• When installing the SST, adjust the position
of each shaft so that they do not interfere
with the vehicle body.
MAIN FRAME

REAR SHAFT

SIDE BAR

FRONT SHAFT

FRONT FOOT No.1

(ADAPTER FOR FRONT SHAFT)

FRONT FOOT No.2

(ADAPTER FOR FRONT SHAFT)
ac9uuw00001980

(1) Install the right rear shaft of the SST to the

bolt of the right shock absorber shown in the 49 C017 5A0
figure.
(2) Install the left rear shaft of the SST to the bolt
of the left shock absorber (Identical position to
the right side).
FRONT
SIDE

ac9uuw00001981

05-17–35
1890-1U-06H(05-17).fm 36 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

(3) Install the left/right front shaft of the SST with RH
front foot No.2 to the bolt shown in the figure. 49 C017 5A0 FRONT SIDE
(4) Adjust the positions of the SST side bars so
that they are the same height (left and right)
and horizontal.
(5) Make sure each joint is securely tightened.

LH FRONT SIDE

ac9uuw00001982

2. Support the engine using the SSTs. 49 C017 5A0

Note
• The SST (49 E017 5A0) can be used in
place of the SST (49 C017 5A0).

3. Remove the No.4 engine mount bracket.

49 C017 5A0

ac9uuw00000187

Transaxle Removal Note

1. Support the transaxle on a jack.
2. Remove the transaxle mounting bolts.
3. Remove the transaxle.

ac9uuw00001983

Transaxle Installation Note

1. Set the transaxle on a jack and lift it.
2. Rotate the drive plate so that the logo mark faces
upward.

ac9uuw00001671

05-17–36
1890-1U-06H(05-17).fm 37 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

3. Rotate the torque converter so that the mark
faces upward.
MARK

ac9uuw00001672

4. Install the transaxle mounting bolts and bracket.

Tightening torque
37—52 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}
05-17

BRACKET
ac9uuw00001669

No.4 Engine Mount Bracket Installation Note

1. Install the No.4 engine mount bracket to the
BOLT D BOLT A
transaxle and temporarily tighten nuts.
2. Temporarily tighten bolt.
3. Temporarily tighten bolt A and nuts B, C.
4. Tighten bolt A, nuts B and C in the order of
B→A→C. NUT B
5. Tighten bolt D.

Tightening torque
Bolt A, Nut B, C: 66.6—93.1 N·m {6.80—9.49
NUT C
kgf·m, 49.2—68.6 ft·lbf}
Bolt D: 74.5—104.9 N·m {7.60—10.69 kgf·m,
ac9uuw00001984
55.0—77.3 ft·lbf}

No.1 Engine Mount Installation Note

1. Install the No.1 engine mount, No.1 engine mount
bracket and the front crossmember as a single
unit. (See 02-13-11 FRONT CROSSMEMBER
REMOVAL/INSTALLATION.)

NO.1 ENGINE
MOUNT
ac9uuw00002246

05-17–37
1890-1U-06H(05-17).fm 38 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

2. Tighten the bolts on the No.1 engine mounting
brakcet in the order of A, B.

Tightening torque
93.1—116.6 N·m {9.50—11.8 kgf·m, 68.7— B
85.9 ft·lbf}

A
FRONT

ac9uuw00000966

3. Teighten the No.1 engine mount bolt C at the

specified torque.

Tightening torque
93.1—116.6 N·m {9.50—11.8 kgf·m, 68.7—
85.9 ft·lbf}

FRONT C

ac9uuw00002248

Torque Converter Nuts Installation Note

1. Align the holes by turning the torque converter.
2. Insert a screwdriver through the converter
housing service hole, and lock the drive plate.

Caution
• Loosely and equally tighten the torque
converter nuts, then further tighten them
to the specified tightening torque.

ac9uuw00001657

3. Tighten the torque converter mounting nuts.

Tightening torque
40.5—54.7 N·m {4.13—5.57 kgf·m, 29.9—40.3
ft·lbf}

NUT

ac9uuw00001668

05-17–38
1890-1U-06H(05-17).fm 39 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

4. Install the cover as shown in the figure.

COVER

FASTENER

ac9uuw00001612
05-17

Selector Cable Installation Note

1. Install the selector lever to the manual shaft lever
so that no load acts on the selector cable. CLIP
UPWARD
Note
• Install the selector lever to the manual shaft
lever with the clip side of the selector cable
end facing up.

2. Confirm that the tip of the manual shaft lever

SELECTOR CABLE
projects out of the end of the selector cable.
End Of Sie
WM: OIL SEAL (DIFFERENTIAL) MANUAL SHAFT LEVER
ac9uuw00001985

OIL SEAL (DIFFERENTIAL) REPLACEMENT [AW6A-EL, AW6AX-EL]

id051723800100
Transaxle Case Side
1. Disconnect the negative battery cable.
2. Drain the ATF. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-
EL].)

Caution
• The oil seal is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines
contact the oil seal.

3. Remove the drive shaft (left side). (See 03-13-14 FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

Caution
• Do not damage the transaxle case.
• Do not damage the differential case.

4. Remove the oil seal lip using a razor.

5. Remove and discard the oil seal using a tape-
wrapped flathead screwdriver.

Caution
• Do not damage the oil seal.

ac9uuw00001679

05-17–39
1890-1U-06H(05-17).fm 40 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

6. Using the SST and a hammer, tap a new oil seal
so that the specified oil seal position is obtained.
Substitution SST
• 49 H028 202 3—4 mm
Outer diameter: 54.5—61 mm {2.15—2.40 in} {0.118—0.157 in}

Inner diameter: 52 mm {2.05 in} or more

Plate thickness: 2 mm {0.08 in} or more
7. Install the drive shaft (left side). (See 03-13-14
FRONT DRIVE SHAFT REMOVAL/
INSTALLATION.)
8. Add ATF to the specified level. (See 05-17-12 49 H028 202
AUTOMATIC TRANSAXLE FLUID (ATF)
ac9uuw00001680
REPLACEMENT [AW6A-EL, AW6AX-EL].)
9. Connect the negative cable.
10. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)

Converter Housing Side (2WD)

1. Disconnect the negative battery cable.
2. Drain the ATF. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-
EL].)

Caution
• The oil seal is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines
contact the oil seal.

3. Remove the drive shaft (right side). (See 03-13-14 FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
4. Remove the joint shaft. (2WD) (See 03-13-4 JOINT SHAFT REMOVAL/INSTALLATION [2WD].)

Caution
• Do not damage the converter housing.
• Do not damage the differential case.

5. Remove the oil seal lip using a razor.

6. Remove and discard the oil seal using a tape-
wrapped flathead screwdriver.

Caution
• Do not damage the oil seal.

ac9uuw00001681

7. Using the SST and a hammer, tap a new oil seal

28—29 mm
so that the specified oil seal position is obtained. {1.11—1.14 in}
Substitution SST
• 49 F027 009
Outer diameter: 76.8 mm {3.02 in}
Plate thickness: 2 mm {0.08 in} or more
8. Install the joint shaft. (2WD) (See 03-13-4 JOINT
SHAFT REMOVAL/INSTALLATION [2WD].)
9. Install the drive shaft (right side). (See 03-13-14
FRONT DRIVE SHAFT REMOVAL/
INSTALLATION.) 49 F027 009
10. Add ATF to the specified level. (See 05-17-12
ac9uuw00001801
AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT [AW6A-EL, AW6AX-EL].)
11. Connect the negative cable.
12. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)

05-17–40
1890-1U-06H(05-17).fm 41 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Converter Housing Side (AWD)
1. Disconnect the negative battery cable.
2. Drain the ATF. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-
EL].)
3. Remove the transaxle. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
4. Remove the converter housing from the transaxle case. (See Automatic Transaxle Workshop Manual [AW6A-
EL, AW6AX-EL].)

Caution
• Do not damage the transaxle case.

5. Remove and discard the oil seal using a tape-

wrapped flathead screwdriver.

Caution
• Do not damage the oil seal.
05-17

ac9uuw00001802

6. Using the SST and a hammer, tap a new oil seal

so that the specified oil seal position is obtained. 49 L033 101
Substitution SST
• 49 L033 101
Outer diameter: 73—76.3 mm {2.88—3.00 in} 33—34 mm
Inner diameter: 69 mm {2.72 in} or more {1.30—1.33 in}
Plate thickness: 2 mm {0.08 in} or more
Length: 20 mm {0.79 in} or more
7. Install the converter housing to the transaxle
case. (See Automatic Transaxle Workshop
Manual [AW6A-EL, AW6AX-EL].)
8. Install the transaxle (See 05-17-30 AUTOMATIC
ac9uuw00001803
TRANSAXLE REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
9. Add ATF to the specified level. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT
[AW6A-EL, AW6AX-EL].)
10. Connect the negative cable.
11. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
End Of Sie

05-17–41
1890-1U-06H(05-17).fm 42 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

DIFFERENTIAL GEAR O-RING REPLACEMENT [AW6A-EL, AW6AX-EL]
id051723800200

Caution
• The O-ring is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines
contact the O-ring.

1. Remove the drive shaft and joint shaft. (See 03-13-4 JOINT SHAFT REMOVAL/INSTALLATION [2WD].) (See
03-13-14 FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

Caution
• Do not damage the differential case.

2. Remove and discard the O-ring using a tape-

wrapped flathead screwdriver.

Caution
• Do not damage the O-ring.
• Do not damage the differential case.

3. Apply ATF to a new O-ring and install it to the

differential case.
4. Install the drive shaft and joint shaft. (See 03-13-4
JOINT SHAFT REMOVAL/INSTALLATION
[2WD].) (See 03-13-14 FRONT DRIVE SHAFT
ac9uuw00001986
REMOVAL/INSTALLATION.)
End Of Sie
CONTROL VALVE BODY REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]
WM: CONTROL VALVE BODY

id051723801800
On-Vehicle Removal

Warning
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eyeglasses whenever using compressed air.

Caution
• Clean the transaxle exterior throughout with a steam cleaner or cleaning solvents before removal.
• If any old sealant gets into the transaxle during installation of the control valve body cover, trouble
may occur in the transaxle case and control valve body cover. Clean with cleaning fluid.

1. Disconnect the negative battery cable.

2. Remove the air cleaner component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
3. Drain the ATF. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-
EL].)
4. Remove the oil cooler.
5. Remove the oil pipe. (See 05-17-52 OIL COOLER OIL
REMOVAL/INSTALLATION [AW6A-EL, AW6AX- COOLER
EL].)

OIL PIPE
ac9uuw00001666

05-17–42
1890-1U-06H(05-17).fm 43 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

6. Remove the control valve body cover installation
bolt.

Caution
• Do not damage the fitting surface of the
transaxle case and the control valve body
cover.
• Do not deform the control valve body
cover.

ac9uuw00001987
05-17
7. Using a plastic hammer, tap the control valve
body cover to remove it.

Caution
• Be careful not to damage the solenoid
valves and connectors.
• Do not pull the wiring harnesses when
removing the connector.

Note
• Disconnect the solenoid connector
according to the following procedure:
ac9uuw00001988

1. Insert a precision screwdriver from the

backside into the connector as shown in
the figure.

ac9uuw00001989

2. Pry the screwdriver in the direction of the

arrow and disconnect the connector.

Caution
• Do not damage the solenoid valves and
connectors with the screwdriver.
• When disconnecting connectors, grasp
the connectors, not the harnesses.
Otherwise, the harnesses may be pulled
out of the connector causing poor
contact.
ac9uuw00001990

05-17–43
1890-1U-06H(05-17).fm 44 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

8. Disconnect the solenoid connectors, VSS
connector and the input/turbine speed sensor CLAMP
connector.
9. Disconnect the coupler component from the CLAMP
clamp.

ac9uuw00001991

10. Remove the lock plate, and pull out the TFT
sensor from the control valve body.
11. Remove the O-ring from the TFT sensor.

Note
• Be sure to secure the coupler component
with tape so that it will not interfere with the
control valve body component.

ac9uuw00001992

12. Fix the coupler component with tape to the

transaxle case as shown in the figure.

ac9uuw00001993

13. Remove the VSS connector and input/turbine speed sensor connector from the solenoid clamp.

VSS CONNECTOR INPUT/TURBINE SPEED SENSOR

CONNECTOR

ac9uuw00001994

05-17–44
1890-1U-06H(05-17).fm 45 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Note
• Be sure to secure the VSS and input/turbine speed sensor with tape so that they will not interfere with the
control valve body component.

14. Fix the VSS wiring harness and input/turbine

speed sensor wiring harness with tape to the
transaxle case as shown in the figure.

ac9uuw00001995

15. Remove the suction cover and the gasket.

05-17
Caution
• Evenly loosen the bolts a little at a time in
the order shown in the figure.

ac9uuw00001996

16. Remove the control valve body installation bolts.

Caution
2
• Do not drop the control valve body
component.
3
6
5

4 1

ac9uuw00001997

05-17–45
1890-1U-06H(05-17).fm 46 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

17. Disconnect the manual valve link and remove the
control valve body component.

ac9uuw00001998

On-Vehicle Installation

Caution
• When installing the control valve body component, do not put the coupler component in the open
space of the separate plate in the control valve body component.
• Do not pinch the coupler component between the separate plate and the control valve body
component.

1. Connect the manual valve link and install the

control valve body component. SEPARATE PLATE

ac9uuw00001999

2. Temporarily install the control valve body

component with the bolts.

Bolt length (measured from below the head) A

A: 31 mm {1.220 in}
B: 17 mm {0.669 in}
C: 21 mm {0.827 in} B
B
B
Note
• Aligning the bolt holes, temporarily tighten
the bolt by hand. C C

ac9uuw00002000

05-17–46
1890-1U-06H(05-17).fm 47 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

3. Temporarily install the suction cover and a new
gasket with the bolts.

ac9uuw00001996
05-17
4. Tighten the bolts in the order shown in the figure.

Tightening torque
5
8—12 N·m {82—122 kgf·cm, 72—105 in·lbf}

4
1
2

3 6

7
8
ac9uuw00002001

5. Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.

VSS CONNECTOR INPUT/TURBINE SPEED SENSOR

CONNECTOR

ac9uuw00001994

05-17–47
1890-1U-06H(05-17).fm 48 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

Caution
• If the control valve body cover is installed with the wiring harnesses overlapped, the wiring
harnesses may be pinched between the cover and valve body causing the wiring harnesses to be
damaged. Therefore, verify that the wiring harnesses are not overlapped when installing the
control valve body cover.

NO GOOD GOOD

ac9uuw00002002

6. Apply ATF to a new O-ring and install it on the TFT sensor.

7. Install the TFT sensor with the lock plate and a
bolt to the control valve body component as
shown in the figure.

Tightening torque
8—12 N·m {82—122 kgf·cm, 72—105 in·lbf}

8. Connect the solenoid connectors, VSS connector

and the input/turbine speed sensor connector.

ac9uuw00002003

9. Connect the coupler component to the clamps.

CLAMP
Note
• Completely remove sealant and oil with CLAMP
white gasoline or similar.

ac9uuw00001991

05-17–48
1890-1U-06H(05-17).fm 49 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

10. Clean sealant and oil off the contact surface of
the transaxle case with the control valve body
cover and the bolt holes.

Note
• Completely remove oil with white gasoline or
similar.

11. Clean oil off the contact surface of the new control
valve body cover with the transaxle case.

05-17

ac9uuw00002004

12. Apply sealant to the new control valve body cover

as shown in the figure.

Caution
• Be careful that the coupler component
will not become caught between the
control valve body cover and transaxle
case.

ac9uuw00002005

13. Install the new control valve body cover with new
seal bolts.

Tightening torque
9.8—15.7 N·m {100—160 kgf·cm, 87—138
in·lbf}

14. Install the oil pipe. (See 05-17-52 OIL COOLER

REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)
15. Install the oil cooler. (See 05-17-52 OIL COOLER
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)
16. Install the TCM. (See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
17. Add ATF to the specified level. (See 05-17-12
AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT [AW6A-EL, AW6AX-EL].) ac9uuw00001987
18. Install the air cleaner component. (See 01-13-4
INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
19. Connect the negative battery cable.
20. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
End Of Sie
WM: TORQUE CONVERTER

05-17–49
1890-1U-06H(05-17).fm 50 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

OIL SEAL (OIL PUMP) REPLACEMENT [AW6A-EL, AW6AX-EL]
id051723800800
1. Remove the transaxle. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)

Caution
• The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
• Do not drop the torque converter.
• Do not pinch fingers.

2. Remove the torque converter. (See 05-17-50 TORQUE CONVERTER REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)

Caution
• Do not to damage the bushing on the oil pump body.

3. Using a tape-wrapped flathead screwdriver,

remove the oil seal from the oil pump body.

ac9uuw00002006

4. Using the SST and a hammer, install the oil seal

to the oil pump body.
Substitution SST
• 49 U027 003 49 U027 003
Outer diameter: 67 mm {2.64 in} or more
Inner diameter: 54—61 mm {2.13—2.40 in}
Plate thickness: 2 mm {0.08 in} or more
5. Coat the lip of the oil seal with grease.
6. Install the torque converter. (See 05-17-50 -0.2—0.2 mm
TORQUE CONVERTER REMOVAL/ {-0.00788—0.00788 in}
INSTALLATION [AW6A-EL, AW6AX-EL].)
7. Install the transaxle. (See 05-17-30 AUTOMATIC
ac9uuw00002007
TRANSAXLE REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
8. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
End Of Sie
TORQUE CONVERTER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]
id051723800700
1. Remove the transaxle. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)

Caution
• The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
• Do not drop the torque converter.
• Do not pinch fingers.

05-17–50
1890-1U-06H(05-17).fm 51 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

2. Remove the torque converter, and immediately
turn it so that the hole faces upward. This will help
to keep any remaining fluid from spilling.
3. Drain any ATF remaining in the torque converter.
4. Using a flathead screwdriver, position the drive
gear on the oil pump component in the center.
5. Install the torque converter to the transaxle.

ac9uuw00001683

6. To ensure that the torque converter is installed

A
accurately, measure distance A between the end
TORQUE CONVERTER
of the torque converter and the end of the
converter housing.

Distance A ((between the end of the torque 05-17

converter and the end of the converter
housing))
20 mm {0.79 in}

7. Install the transaxle. (See 05-17-30 AUTOMATIC

TRANSAXLE REMOVAL/INSTALLATION [AW6A-
ac9uuw00002008
EL, AW6AX-EL].)
8. Perform the mechanical system test. (See 05-17-
3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
End Of Sie
OIL COOLER FLUSHING [AW6A-EL, AW6AX-EL]
WM: OIL COOLER

id051723801500

Note
• If the automatic transaxle is replaced, flush and inspect the oil cooler.
• When replacing the automatic transaxle, inspect the oil cooler together with flushing it using the following
procedure, and with the oil cooler hose removed.

1. Disconnect the oil cooler hose.

2. Set a clean oil pan up to the oil cooler hose inlet.
3. Blow 491—882 kPa {5—9 kgf/cm2, 72—127 psi}
of compressed air from the oil cooler hose outlet
to drain remaining oil. OIL COOLER
4. Add new ATF from the oil cooler hose outlet and
OIL PAN
blow 491—882 kPa {5—9 kgf/cm2, 72—127 psi}
of compressed air to flush. (Repeat 2 or 3 times)
5. Verify that none of the following foreign material is
mixed in with the drained ATF: COMPRESSED
• Large metal fragments of φ 0.5 mm {0.02 mm} AIR
or more that cannot pass through the oil
strainer
• Fibrous clutch facing
6. Repeat the procedures from Step 1 to 2 and flush
the inside of the oil cooler.
7. If foreign material such as metal fragments or FLUSHING IN
clutch facing remains even after the oil cooler is
flushed repeatedly, replace the oil cooler
(radiator).
End Of Sie

FLUSHING OUT

ac9uuw00001709

05-17–51
1890-1U-06H(05-17).fm 52 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]
id051723801600
1. Disconnect the negative battery cable.
2. Drain the ATF into a container. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT
[AW6A-EL, AW6AX-EL].)
3. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Add the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
7. Add ATF to the specified level. (See 05-17-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT
[AW6A-EL, AW6AX-EL].)
8. Connect the negative battery cable.
9. Inspect for oil leakage from the oil pipes and oil hoses.
10. Inspect for coolant from the hoses.
11. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5].)
12. Inspect the ATF level and condition. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION
[AW6A-EL, AW6AX-EL].)
13. Perform the line pressure test. (See 05-17-3 MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)

05-17–52
1890-1U-06H(05-17).fm 53 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

7 R

5 R
8 6
C
D 7 R
7
E D R
E 7 R

C
4 05-17
11 9
19—25
{2.0—2.5, 19.6—29.4
14—18} {2.00—2.99,
14.5—21.6}
R 2
1
1 2 R
3 R
R 2

2 R
1
R 2 B
A

10 CLIP

N·m {kgf·m, ft·lbf}

ac9uuw00001704

1 Oil hose A 6 Oil hose B

(See05-17-54 Oil Pipe, Hose Clamp, Oil Hose (See05-17-54 Oil Pipe, Hose Clamp, Oil Hose
Installation Note.) Installation Note.)
2 Hose clamp A 7 Hose clamp D
(See05-17-54 Oil Pipe, Hose Clamp, Oil Hose (See05-17-54 Oil Pipe, Hose Clamp, Oil Hose
Installation Note.) Installation Note.)
3 Hose clamp B 8 Oil hose C
(See05-17-54 Oil Pipe, Hose Clamp, Oil Hose (See05-17-54 Oil Pipe, Hose Clamp, Oil Hose
Installation Note.) Installation Note.)
4 Oil pipe A 9 Oil pipe B
(See05-17-54 Oil Pipe, Hose Clamp, Oil Hose (See05-17-54 Oil Pipe, Hose Clamp, Oil Hose
Installation Note.) Installation Note.)
5 Hose clamp C
(See05-17-54 Oil Pipe, Hose Clamp, Oil Hose
Installation Note.)

05-17–53
1890-1U-06H(05-17).fm 54 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

10 Radiator (in tank oil cooler)
(See 01-12-8 RADIATOR REMOVAL/
INSTALLATION [MZI-3.5].)
(See 05-17-54 Radiator (In Tank Oil Cooler)
Installation Note.)
11 Oil cooler

Radiator (In Tank Oil Cooler) Installation Note

1. The automatic transaxle oil cooler flushing must be performed whenever a transaxle is removed for service
because the existing fluid may be contaminated, and to prevent contamination of new fluid.

Note
• Flushing must be performed after installation of an overhauled or replaced transaxle.

2. Follow the instructions in the manufacturer’s publication for flushing operation.

Oil Pipe, Hose Clamp, Oil Hose Installation Note

1. Apply compressed air to the cooler-side opening,
and blow any remaining grime and foreign
material from the cooler pipes. Compressed air
should be applied for no less than 1 min.

ac9uuw00001936

2. Align the marks, and slide the oil hose onto the oil
pipe until it is fully seated as shown in the figure. OIL PIPE

Note MARK
OIL PIPE
• If reusing the hose, install the new hose
clamp exactly on the mark left by the
previous hose camp.

3. Install the new hose clamp onto the hose. OIL HOSE
4. Verify that the hose clamp does not interfere with OIL HOSE
any other components.
End Of Sie ac9uuw00001937

05-17–54
1890-1U-06H(05-17).fm 55 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

OIL COOLER DISASSEMBLY/ASSEMBLY [AW6A-EL, AW6AX-EL]
id051723801700
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

05-17
6

R 3
4 R

2 5
1.8—2.2
{19—22, 16—19}
1
N·m {kgf·cm, in·lbf}

ac9uuw00001659

1 Mount rubber 5 Drain cock

2 Radiator outer tank (in tank oil cooler) 6 ATF cooler
(See 05-17-55 Radiator Outer Tank (In Tank Oil 7 Radiator
Cooler) Removal Note.)
(See 05-17-56 Radiator Outer Tank (In Tank Oil
Cooler) Installation Note.)
3 O-ring
4 Washer

Radiator Outer Tank (In Tank Oil Cooler) Removal Note

1. Inspect the height of the header tabs.
2. Insert the end of a medium tip screwdriver RADIATOR
between the end of the header tab and the outer LOWER
tank. TANK

Note
• Do not open more tabs than necessary for HEADER TAB
tank removal. HEIGHT

O-RING

ac9uuw00001938

05-17–55
1890-1U-06H(05-17).fm 56 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

3. Pivot the screwdriver to pry the tab away from the
tank and repeat the procedure for each tab.
4. Remove the radiator outer tank and O-ring
(gasket) from the core header when all of the tabs
SCREWDRIVER
are opened.

Note
• If any header tabs are missing from the core,
replace the radiator.

5. Inspect the gasket surface of the radiator core

header to ensure it is clean and free of foreign
ac9uuw00001939
material or damage.
6. Inspect the radiator outer tank for warping. If it is
warped, replace radiator tank.

Radiator Outer Tank (In Tank Oil Cooler) Installation Note

1. Install a new O-ring and ensure it is not twisted.
2. Position the radiator tank in the original direction
to the core using care not to scratch the tank
O-RING
sealing surface with the header tabs.

Note
• Step 3 will set jaw opening to the correct
specification.

ac9uuw00001940

3. With the jaws of locking-type pliers (vise grips)

closed and locked, turn the adjusting screw to LOCKING TYPE PLIERS
position the jaws against the drill bit with the ADJUSTING
(VISE PLIERS)
diameter measured (height) in the removal LOCKNUT SCREW
procedure 1. Tighten the lock nut on the adjusting
screw against the handle to lock the adjustment in
place.

DRILL BIT

ac9uuw00001941

05-17–56
1890-1U-06H(05-17).fm 57 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

4. Squeeze the header tabs down in the order as
shown against the lip of the radiator outer tank RADIATOR LOWER
TANK
base with the locking-type pliers while rotating the
pliers toward the tank.

LOCKING TYPE
PLIERS

6 7 05-17
2
3 4

1
8 5
ac9uuw00001942

5. Verify that the height of the header tabs is same

as the height before removal. RADIATOR
6. Inspect for leakage from radiator. (See 01-12-6 LOWER
ENGINE COOLANT LEAKAGE INSPECTION TANK
[MZI-3.5].)
End Of Sie
WM: DRIVE PLATE

HEADER TAB
HEIGHT

O-RING

ac9uuw00001938

05-17–57
1890-1U-06H(05-17).fm 58 ページ ２００６年１２月１９日　火曜日　午前１１時５４分

AUTOMATIC TRANSAXLE [AW6A-EL, AW6AX-EL]

DRIVE PLATE REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]
id051723802500
1. Remove the transaxle. (See 05-17-30 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
2. Remove in the order indicated in the figure.
1 Drive plate mounting bolts
(See05-17-58 Drive Plate Mounting Bolts Removal
Note.)
SST
2 Backing plate
73—87
3 Drive plate {7.5—8.8, 53.9—64.1}
(See05-17-58 Drive Plate Installation Note.) R 1
3. Install in the reverse order of removal.
2 3
N·m {kgf·m, ft·lbf}
ac9uuw00001800

Drive Plate Mounting Bolts Removal Note

1. Set the SST or equivalent against the drive plate.
2. Remove the bolts and the drive plate.

49 E011 1A0

ac9uuw00001686

Drive Plate Installation Note

1. Remove the sealant from the bolt holes in the crankshaft and from the drive plate mounting bolts.
2. Install the drive plate.
3. Install the backing plate.
4. Set the SST or equivalent against the drive plate.
5. Tighten the new drive plate mounting bolts in two
or three steps in the order shown.
49 E011 1A0
Tightening torque 1
73—87 N·m {7.5—8.8 kgf·m, 53.9—64.1 ft·lbf} 3 8
5 6
6. Install the transaxle. (See 05-17-30 AUTOMATIC 7 4
TRANSAXLE REMOVAL/INSTALLATION [AW6A- 2
EL, AW6AX-EL].)
End Of Sie
ac9uuw00001687

05-17–58
1890-1U-06H(05-18).fm 1 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

05-18 AUTOMATIC TRANSAXLE SHIFT MECHANISM
AUTOMATIC TRANSAXLE SHIFT SELECTOR LEVER COMPONENT
MECHANISM LOCATION INDEX . . . . . 05-18–2 INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-18–7
SHIFT-LOCK INSPECTION. . . . . . . . . . . 05-18–2 SELECTOR CABLE
KEY INTERLOCK INSPECTION. . . . . . . 05-18–3 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 05-18–7
INTERLOCK CABLE SELECTOR LEVER COMPONENT
INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-18–3 REMOVAL/INSTALLATION . . . . . . . . . . 05-18–8
INTERLOCK CABLE Selector Cable Removal Note . . . . . . . . 05-18–9
ADJUSTMENT . . . . . . . . . . . . . . . . . . . 05-18–3 Selector Cable Installation Note . . . . . . 05-18–9
SELECTOR LEVER Interlock Cable Installation Note . . . . . . 05-18–10
INSPECTION . . . . . . . . . . . . . . . . . . . . . 05-18–6

End of Toc
WM: AUTOMATIC TRANSAXLE

05-18

05-18–1
1890-1U-06H(05-18).fm 2 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

AUTOMATIC TRANSAXLE SHIFT MECHANISM LOCATION INDEX
id051800801000

2
3

ac9uuw00001608
.

1 Interlock cable 3 Selector lever

(See 05-18-3 KEY INTERLOCK INSPECTION.) (See 05-18-2 SHIFT-LOCK INSPECTION.)
(See 05-18-3 INTERLOCK CABLE INSPECTION.) (See 05-18-6 SELECTOR LEVER INSPECTION.)
(See 05-18-3 INTERLOCK CABLE (See 05-18-7 SELECTOR LEVER COMPONENT
ADJUSTMENT.) INSPECTION.)
2 Selector cable (See 05-18-8 SELECTOR LEVER COMPONENT
(See 05-18-7 SELECTOR CABLE ADJUSTMENT.) REMOVAL/INSTALLATION.)

End Of Sie
SHIFT-LOCK INSPECTION
WM: SHIFT LOCK SYSTEM

id051800800400
1. Turn the ignition switch to the ON position.
2. Verify that the selector lever is in the P position.
3. Verify that the selector lever cannot be shifted from the P position without depressing the brake pedal.
4. Depress the brake pedal and verify that the selector lever cannot be shifted from the P position.
• If there is any malfunction, inspect the interlock cable.
(See 05-18-3 INTERLOCK CABLE INSPECTION.)

05-18–2
1890-1U-06H(05-18).fm 3 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

End Of Sie

KEY INTERLOCK INSPECTION

WM: KEY INTERLOCK SYSTEM

id051800800100
1. Verify that the ignition key cannot be pulled out except in the P position.
• If there is any malfunction, inspect the interlock cable. (See 05-18-3 INTERLOCK CABLE INSPECTION.)
End Of Sie
INTERLOCK CABLE INSPECTION
id051800800200
1. Turn the ignition switch to the ON position. (Engine off)
2. Remove the clip of the selector lever base plate,
then remove the interlock cable from the U-
groove.
3. Remove the interlock cable from the selector
lever.
INTERLOCK
CABLE

CLIP

05-18
ac9uuw00001580

4. Verify that the interlock cable moves freely with

the brake pedal depressed.
• If there is any malfunction, inspect the
interlock cable for abnormal winding. If any INTERLOCK CABLE
abnormal winding found, correct it.
• If the malfunction persists after correcting the
interlock cable winding, replace it.
End Of Sie

ac9uuw00002009

INTERLOCK CABLE ADJUSTMENT

id051800800300
1. Turn the ignition switch to the ON position. (Engine off)
2. Pull up the lock piece of the interlock cable to
release the lock.
LOCK PIECE

INTERLOCK CABLE
UNLOCK LOCK

ac9uuw00002010

3. Remove the clip of the selector lever base plate,

then remove the interlock cable from the U-
groove.
4. Remove the interlock cable from the selector
lever.
INTERLOCK
CABLE

CLIP

ac9uuw00001581

05-18–3
1890-1U-06H(05-18).fm 4 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

5. Remove the lock unit from the bracket.

LOCK UNIT

BRACKET
ac9uuw00002011

6. Verify that the marking on the slider pin is

positioned as shown in the figure. SLIDER PIN

MARKING

ac9uuw00002205

7. Push the interlock cable.

INTERLOCK CABLE

ac9uuw00002013

8. Insert the a 1.5mm {0.059 in} round bar or similar

into hole A with the slider pin fully pushed in.
LOCK UNIT INTERLOCK
CABLE
C

A B BRAKE SWITCH
SLIDER PIN

ac9uuw00002014

05-18–4
1890-1U-06H(05-18).fm 5 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

9. Fully pull the end of the interlock cable.

INTERLOCK CABLE

ac9uuw00002015

10. Push the a 1.5mm {0.059 in} round bar or similar

into hole B and hole C of the lock unit until it LOCK UNIT INTERLOCK
passes through. CABLE
C
11. Disconnect the brake switch connector.
12. Remove the brake switch. (See 04-11-4 BRAKE A B BRAKE SWITCH
PEDAL REMOVAL/INSTALLATION.) SLIDER PIN 05-18
13. Install a new brake switch. (See 04-11-4 BRAKE
PEDAL REMOVAL/INSTALLATION.)

Caution
• Do not connect the brake switch
connector until the interlock cable
ac9uuw00002014
adjustment is completed.

14. Install the lock unit to the bracket. (See 05-18-8 SELECTOR LEVER COMPONENT REMOVAL/
INSTALLATION.)
15. Rotate the slider pin to release the lock and verify that it slides freely.
16. Verify that the slider pin contacts the brake pedal
stopper rubber and rotate the slider pin to lock.
SLIDER PIN
UNLOCK

LOCK

MARKING

ac9uuw00002206

17. Install the interlock cable end to the interlock link

on the selector lever.
18. Fit the interlock cable in the U-groove in the
selector lever base plate and install the clip.
INTERLOCK
CABLE

CLIP

ac9uuw00002017

05-18–5
1890-1U-06H(05-18).fm 6 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

19. Press the interlock cable lock piece in until it is
locked.
LOCK PIECE
Caution
• Applying a load to the interlock cable
while pressing the lock piece in can
affect the lock unit operation.

INTERLOCK CABLE
UNLOCK LOCK

ac9uuw00002018

20. Remove the a 1.5mm {0.059 in} round bar or

similar from the lock unit holes A, B, and C. LOCK UNIT INTERLOCK
21. Connect the brake switch connector with the CABLE
C
brake pedal released.
A B BRAKE SWITCH
Caution SLIDER PIN
• The clearance between the brake switch
and the brake pedal is automatically
adjusted to the correct amount when the
brake switch connector is connected
after the brake switch has been properly
installed. If the brake switch is not
ac9uuw00002014
properly installed or the connector is
connected before installation, the
clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the
brake switch is properly installed before connecting the connector.
• Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again.
Therefore, replace the switch with a new one when replacing the power brake unit or the pedal, or
performing any procedure that changes the pedal stroke.

22. Inspect shift lock operation. (See 05-18-2 SHIFT-LOCK INSPECTION.)

End Of Sie
SELECTOR LEVER INSPECTION
WM: SELECTOR LEVER COMPONENT

id051800800500
1. Turn the ignition switch to the ON position. (engine OFF)
2. With the brake pedal depressed, verify that there
is a “click” at each range when shifted.
3. Verify that the selector lever can be shifted.
4. Verify that there is a “click” at each position when
OPERATION WHEN
shifted from P position to M range. BRAKE PEDAL IS
DEPRESSED

OPERATION WHEN
BRAKE PEDAL IS
RELEASED

ac9uuw00002019

5. Verify that the positions of the selector lever and

the indicator are aligned. SELECTOR INDICATOR
• If there is any malfunction, adjust the TR LIGHT
switch. (See 05-17-26 TCM REMOVAL/
INSTALLATION [AW6A-EL, AW6AX-EL].)
6. Verify that the vehicle operates in each selected
range.
End Of Sie

ac9uuw00001582

05-18–6
1890-1U-06H(05-18).fm 7 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

SELECTOR LEVER COMPONENT INSPECTION
id051800800600
1. Disconnect the negative battery cable.
2. Remove the center console.
3. Remove the dashboard completely. (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
4. Disconnect the selector lever component connector.
5. Inspect for continuity at the selector lever
component.
• If there is any malfunction, adjust the selector
cable. (See 05-18-7 SELECTOR CABLE E C A
ADJUSTMENT.) F D B

: Continuity
Selector lever Connector terminal
position/range A B C D E F
-M
M range center M
+M
ac9uuw00002020
Other 05-18
ac9uuw00002021

End Of Sie
SELECTOR CABLE ADJUSTMENT
id051800800700
1. Remove the center console.
2. Shift the selector lever to P position.
3. Unlock the lock piece of the selector cable
(selector lever side) in the order shown in the
figure. 1
4. Verify that the manual shaft is in P position.

SELECTOR CABLE

ac9uuw00002022

5. Lock the lock piece of the selector cable (selector

lever side) in the order shown in the figure.
6. Install the center console. 1
7. Shift the selector lever from P position to M range,
and make sure that there are no other
components in that area to interfere with the lever.
End Of Sie 2

SELECTOR CABLE

ac9uuw00001594

05-18–7
1890-1U-06H(05-18).fm 8 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION
id051800800800
1. Disconnect the negative battery cable.
2. To remove the interlock cable, remove the following parts.
(1) Column cover (See 09-17-8 COLUMN COVER REMOVAL/INSTALLATION.)
(2) Driver side under panel
(3) Accelerator pedal (See 01-13-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZI-3.5].)
3. To remove the selector cable, remove the following parts.
(1) Battery and battery tray
(2) Air cleaner component (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
(3) Dashboard (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
(4) Front A/C unit (See 07-11-3 FRONT A/C UNIT REMOVAL/INSTALLATION.)
4. To remove the selector lever, remove the following parts.
(1) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
5. Remove in the order shown in the figure.
6. Install in the reverse order of removal. .

6.9—9.8 N·m
{71—99 kgf·cm, 62—86 in·lbf}

4
CLIP
8 15.7—22.5
{1.61—2.29, 11.6—16.5}

3
A
A
5
2
9
1
10

11

7
12
6

B B

13

N·m {kgf·m, ft·lbf}

ac9uuw00001588

1 Clip 8 Selector cable

2 Clip (See05-18-9 Selector Cable Removal Note.)
(See05-18-9 Selector Cable Installation Note.)
3 Clip
9 Selector lever component connector
4 Lock unit connector
10 Selector lever component
5 Interlock cable
(See05-18-10 Interlock Cable Installation Note.) 11 Selector lever knob
6 Clip 12 Selector lever panel
7 Clip 13 Selector lever

05-18–8
1890-1U-06H(05-18).fm 9 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

Selector Cable Removal Note
1. Remove the clip.
2. Remove the selector cable.
CLIP

TCM SELECTOR
CABLE

MANUAL
SHAFT
LEVER

ac9uuw00001591

3. Remove the selector cable from the cable

bracket.
CLIP
05-18
CABLE
BRACKET
SELECTOR
CABLE

ac9uuw00001592

Selector Cable Installation Note

1. Install the selector cable and clip to the bracket as
shown in the figure.
CLIP
Note
• Steps 2 and 3 are for the selector cable CABLE
replacement only. BRACKET
SELECTOR
CABLE
2. Verify that the selector lever is in the P position.

ac9uuw00001593

3. Lock the lock piece of the selector cable (selector

lever side) in the order shown in the figure.
1

SELECTOR CABLE

ac9uuw00001594

05-18–9
1890-1U-06H(05-18).fm 10 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

4. Verify that the manual shaft is in the P position.

Caution
• Bending the selector cable in the manner
shown in the figure will damage the cable
and it may become loose when shifted.
When installing the selector cable, hold it DO NOT BEND
straight.

ac9uuw00001595

5. Install the clip as shown in the figure.

CLIP

ac9uuw00001596

Note CLIP
• Install the selector lever to the manual shaft UPWARD
lever with the clip side of the selector cable
end facing up.

6. Install the selector lever to the manual shaft lever

so that no load acts on the selector cable.
7. Confirm that the tip of the manual shaft lever
SELECTOR CABLE
projects out of the end of the selector cable.
8. Securely install the selector cable to the selector
MANUAL SHAFT LEVER
cable bracket.
ac9uuw00001597

Interlock Cable Installation Note

1. Push the interlock cable.

INTERLOCK CABLE

ac9uuw00001598

05-18–10
1890-1U-06H(05-18).fm 11 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

2. Verify that the marking on the slider pin is
positioned as shown in the figure.

LOCK UNIT

BRACKET
ac9uuw00001599

3. Push the a 1.5mm {0.059 in} round bar or similar

into hole A by fully pushing the slider pin in. LOCK UNIT INTERLOCK
CABLE
C

A B BRAKE SWITCH
SLIDER PIN 05-18

ac9uuw00001600

4. Fully pull the end of the interlock cable.

INTERLOCK CABLE

ac9uuw00001601

5. Push the a 1.5mm {0.059 in} round bar or similar

into hole B and hole C of the lock unit until it LOCK UNIT INTERLOCK
passes through. CABLE
C
6. Disconnect the brake switch connector.
7. Remove the brake switch. (See 04-11-4 BRAKE A B BRAKE SWITCH
PEDAL REMOVAL/INSTALLATION.) SLIDER PIN
8. Install a new brake switch. (See 04-11-4 BRAKE
PEDAL REMOVAL/INSTALLATION.)

Caution
• Do not connect the brake switch
connector until the interlock cable is
ac9uuw00001600
installed.

05-18–11
1890-1U-06H(05-18).fm 12 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

9. With the slider pin pressed, slide the lock unit to
SLIDER PIN
fix the lock unit hook into the bracket hole
securely as shown in the figure.

Caution
• Allowing the interlock cable to be bent or BRACKET
twisted during installation can affect the
lock unit operation.
LOCK UNIT
10. Rotate the slider pin to release the lock and verify
that it slides freely.
ac9uuw00001602

11. Pull the slider pin outward until it contacts the

brake pedal stopper rubber and rotate the slider
SLIDER PIN
pin to lock.
12. Verify that the selector lever in the P position. UNLOCK

LOCK

MARKING

ac9uuw00002204

13. Install the interlock cable end to the cam pin on

the selector lever.
14. Fit the interlock cable in the U–groove in the
selector lever base plate and install the clip.
INTERLOCK
CABLE

CLIP

ac9uuw00001587

15. Press the interlock cable lock piece in until it is

locked.
LOCK PIECE
Caution
• Applying a load to the interlock cable
while pressing the lock piece in can
affect the lock unit operation.

INTERLOCK CABLE
UNLOCK LOCK

ac9uuw00001604

16. Remove the a 1.5mm {0.059 in} round bar or

similar from the lock unit holes A, B, and C. LOCK UNIT INTERLOCK
CABLE
C

A B BRAKE SWITCH
SLIDER PIN

ac9uuw00001600

05-18–12
1890-1U-06H(05-18).fm 13 ページ ２００６年１２月１９日　火曜日　午前１１時５８分

AUTOMATIC TRANSAXLE SHIFT MECHANISM

17. Connect the brake switch connector with the brake pedal released.

Caution
• The clearance between the brake switch and the brake pedal is automatically adjusted to the
correct amount when the brake switch connector is connected after the brake switch has been
properly installed. If the brake switch is not properly installed or the connector is connected
before installation, the clearance may be incorrect, causing a brake light malfunction. Therefore,
always verify that the brake switch is properly installed before connecting the connector.
• Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again.
Therefore, replace the switch with a new one when replacing the power brake unit or the pedal, or
performing any procedure that changes the pedal stroke.

18. Turn the ignition switch to ON position.

19. Install the interlock cable to the steering lock.
20. Slide the outer casing to the steering lock and
insert the clip over the convex part of the outer
casing.
End Of Sie
05-18

CONVEX PART

CLIP

ac9uuw00001605

05-18–13
1890-1U-06H(05-50).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時１分

TECHNICAL DATA
05-50 TECHNICAL DATA
TRANSMISSION/TRANSAXLE
TECHNICAL DATA . . . . . . . . . . . . . . . . 05-50–1

End of Toc
TRANSMISSION/TRANSAXLE TECHNICAL DATA
WM: TRANSMISSION/TRANSAXLE

id055000800100
[AW6A-EL, AW6AX-EL]
Item Specification
N position → D range: 1.5 s or less
Average time lag
N position → R position: 1.5 s or less
Type: JWS3309
ATF
Capacity (Approx. quantity): 7.0 L {7.4 US qt, 6.2 lmp qt}
Distance A ((between the end of the torque converter
20 mm {0.79 in}
and the end of the converter housing))
05-50
Line pressure
Position/range Line pressure (kPa {kgf/cm2, psi})
D, M Idle 350—410 {3.6—4.1, 51—59}
R Idle 580—670 {6.0—6.8, 85—97}

Engine stall speed

Position/range Engine stall speed (rpm)
D, M
2,435
R

Transaxle fluid temperature (TFT) sensor

ATF temperature (°C {°F}) Resistance (kilohm)
10 {50} 5.62—7.31
25 {77} Approx. 3.5
110 {230} 0.22—0.27

Input/turbine speed sensor

Signal Current (mA)
High 12.0—16.0
Low 4.0—8.0

VSS
Signal Current (mA)
High 12.0—16.0
Low 4.0—8.0

Solenoid valve resistance (ATF temperature: 20 °C {68 °F})

Terminal Solenoid valve Resistance (ohm)
B5—GND Shift solenoid A 11—15
B2—GND Shift solenoid B 11—15
B11—B10 Shift solenoid C 5.0—5.6
B17—B18 Shift solenoid D 5.0—5.6
B14—B22 Shift solenoid E 5.0—5.6
B21—B16 Shift solenoid F 5.0—5.6
B9—B4 TCC control solenoid 5.0—5.6
B3—B1 Line pressure control solenoid 5.0—5.6

End Of Sie

05-50–1
1890-1U-06H(05-60).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時４４分

SERVICE TOOLS
05-60 SERVICE TOOLS
TRANSMISSION/TRANSAXLE SST. . . . 05-60–1

End of Toc
TRANSMISSION/TRANSAXLE SST
AT: TRANSMISSION/TRANSAXLE

id056000500100
1: Mazda SST number
2: Global SST number
Example
1:49 UN30 3009
2:303-009

Crankshaft
damper
remover

05-60

1:49 0378 400C 1:49 B019 901B 1:49 HD64

2: – 2: – 406A
2: –
Oil pressure Oil pressure
gauge set gauge Adapter

1:49 C017 5A0* 1:49 H028 202 1:49 F027 009

2: – 2: – 2: –

Engine support Block L Attachment for

68&77 (Part of
49 F027 0A1)

1:49 L033 101 1:49 U027 003 1:49 F026 102

2: – 2: – 2: –

Oil seal installer Oil seal installer Bearing

replacer

1:49 G030 797 1:49 E011 1A0

2: – 2: –

Handle Ring gear brake

set –

* : The SST (49 E017 5A0) can be used in place of the SST (49 C017 5A0).

End Of Sie

05-60–1
1890-1U-06H(06-10).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時４５分

STEERING 06
SECTION

Toc of SCT PROCEDURES . . . . 06-10

GENERAL TECHNICAL DATA . . . . . . . . . . 06-50
POWER STEERING . . . . . . . . . 06-14 SERVICE TOOLS . . . . . . . . . . . 06-60
Toc of SCT
06-10 GENERAL PROCEDURES
GENERAL PROCEDURES Connector Disconnection . . . . . . . . . . . 06-10–1
(STEERING) . . . . . . . . . . . . . . . . . . . . . . 06-10–1 Power Steering Components
Wheels and Tire Installation . . . . . . . . . 06-10–1 Removal/Installation . . . . . . . . . . . . . . 06-10–1

End of Toc 06-10

GENERAL PROCEDURES (STEERING)
WM: STEERING

id061000800100
Wheels and Tire Installation
1. When installing the wheels and tires, tighten the
wheel nuts in a criss-cross pattern to the following
tightening torque.

Tightening torque 1
107.8—147.0 N·m {11.0—14.9 kgf·m, 79.6— 4 3
108.4 ft·lbf}
2 5

amxuuw0000031

Connector Disconnection
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)

Power Steering Components Removal/Installation

1. If any power steering fluid line has been disconnected anytime during the procedure, add ATF M-III, M-V or
Dexron®II, bleed the fluid lines, and inspect for leakage after the procedure has been completed.
End Of Sie

06-10–1
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POWER STEERING
06-14 POWER STEERING
STEERING LOCATION INDEX . . . . . . . . 06-14–2 Holder, Oil Seal (Holder Side)
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . 06-14–3 Disassembly Note . . . . . . . . . . . . . . . . 06-14–12
POWER STEERING FLUID Adjusting Cover
INSPECTION . . . . . . . . . . . . . . . . . . . . . 06-14–3 Disassembly Note . . . . . . . . . . . . . . . . 06-14–13
Fluid Level Inspection . . . . . . . . . . . . . 06-14–3 Oil Seal (Gear Housing Side), Inner
Fluid Leakage Inspection . . . . . . . . . . . 06-14–3 Guide Disassembly Note. . . . . . . . . . . 06-14–13
Fluid Pressure Inspection . . . . . . . . . . 06-14–4 Mounting Rubber
STEERING WHEEL AND Disassembly Note . . . . . . . . . . . . . . . . 06-14–13
COLUMN INSPECTION . . . . . . . . . . . . 06-14–5 STEERING GEAR AND
Steering Wheel LINKAGE INSPECTION . . . . . . . . . . . . . 06-14–14
Play Inspection. . . . . . . . . . . . . . . . . . 06-14–5 Rack Inspection. . . . . . . . . . . . . . . . . . . 06-14–14
Steering Wheel Tie-rod End Inspection . . . . . . . . . . . . . 06-14–14
Looseness Inspection . . . . . . . . . . . . 06-14–5 Tie rod Inspection . . . . . . . . . . . . . . . . . 06-14–14
Steering Wheel STEERING GEAR AND LINKAGE
Effort Inspection . . . . . . . . . . . . . . . . . 06-14–5 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 06-14–15
STEERING WHEEL AND COLUMN Mounting Rubber Assembly Note . . . . . 06-14–16
REMOVAL/INSTALLATION. . . . . . . . . . 06-14–6 Steering Rack, Oil Seal
Steering Wheel Removal Note. . . . . . . 06-14–7 (Gear Housing Side), Inner
Steering Shaft Removal Note. . . . . . . . 06-14–7 Guide Assembly Note . . . . . . . . . . . . . 06-14–17 06-14
Steering Lock Mounting Bolts Oil Seal (Holder Side)
Removal Note . . . . . . . . . . . . . . . . . . 06-14–7 Assembly Note . . . . . . . . . . . . . . . . . . 06-14–18
Key Cylinder (Without Advanced Holder Assembly Note . . . . . . . . . . . . . 06-14–18
Keyless System) Removal Note. . . . . 06-14–7 Adjusting Cover Assembly Note . . . . . . 06-14–18
Steering Lock Mounting Bolts Lock Washer, Tie Rod
Installation Note . . . . . . . . . . . . . . . . . 06-14–8 Assembly Note . . . . . . . . . . . . . . . . . . 06-14–19
Steering Shaft Installation Note . . . . . . 06-14–8 POWER STEERING OIL PUMP
Steering Wheel Installation Note . . . . . 06-14–8 REMOVAL/INSTALLATION . . . . . . . . . . 06-14–20
STEERING SHAFT INSPECTION. . . . . . 06-14–8 Power Steering Fluid Tank
STEERING GEAR AND LINKAGE Removal Note . . . . . . . . . . . . . . . . . . . 06-14–20
REMOVAL/INSTALLATION. . . . . . . . . . 06-14–9 POWER STEERING OIL PUMP
Steering Gear and Linkage DISASSEMBLY/ASSEMBLY . . . . . . . . . 06-14–21
Installation Note . . . . . . . . . . . . . . . . . 06-14–10 Power Steering Oil Pump Component
Bolt (Intermediate Shaft) Disassembly Note . . . . . . . . . . . . . . . . 06-14–22
Installation Note . . . . . . . . . . . . . . . . . 06-14–10 Shaft Component
STEERING GEAR AND LINKAGE Disassembly Note . . . . . . . . . . . . . . . . 06-14–22
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 06-14–10 Oil Seal Assembly Note . . . . . . . . . . . . 06-14–22
Tie-rod End Disassembly Note . . . . . . 06-14–12 Side Plate Assembly Note. . . . . . . . . . . 06-14–22
Lock Washer, Tie Rod Rotor Assembly Note . . . . . . . . . . . . . . 06-14–23
Disassembly Note . . . . . . . . . . . . . . . 06-14–12 Cam Ring Assembly Note . . . . . . . . . . . 06-14–23
Rear Pump Body
Assembly Note . . . . . . . . . . . . . . . . . . 06-14–23

End of Toc
WM: STEERING

06-14–1
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POWER STEERING
STEERING LOCATION INDEX
id061400800100

3
2

ac9uuw00001388

1 Power steering fluid tank 4 Steering gear and linkage

(See 06-14-3 POWER STEERING FLUID (See 06-14-9 STEERING GEAR AND LINKAGE
INSPECTION.) REMOVAL/INSTALLATION.)
2 Steering wheel and column (See 06-14-10 STEERING GEAR AND LINKAGE
(See 06-14-5 STEERING WHEEL AND COLUMN DISASSEMBLY.)
INSPECTION.) (See 06-14-14 STEERING GEAR AND LINKAGE
(See 06-14-6 STEERING WHEEL AND COLUMN INSPECTION.)
REMOVAL/INSTALLATION.) (See 06-14-15 STEERING GEAR AND LINKAGE
ASSEMBLY.)
3 Steering shaft
(See 06-14-8 STEERING SHAFT INSPECTION.) 5 Power steering oil pump
(See 06-14-20 POWER STEERING OIL PUMP
REMOVAL/INSTALLATION.)
(See 06-14-21 POWER STEERING OIL PUMP
DISASSEMBLY/ASSEMBLY.)

End Of Sie

06-14–2
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POWER STEERING
AIR BLEEDING
id061400800200

Caution
• Do not turn the steering wheel during the fluid level inspection, otherwise the fluid level changes
and cannot be inspected correctly.

1. Inspect the fluid level. (See06-14-3 POWER STEERING FLUID INSPECTION.)

2. Jack up the front of the vehicle and support it on safety stands.
3. Turn the steering wheel fully to the left and right several times with the engine not running.
4. Reinspect the fluid level.
• If it has dropped, add fluid.
5. Repeat Steps 3 and 4 until the fluid level stabilizes.
6. Lower the vehicle.
7. Start the engine and let it idle.
8. Turn the steering wheel fully to the left and right several times.
9. Verify that the fluid is not foamy and that the fluid level has not dropped.
• If the fluid level has dropped, add fluid as necessary and repeat Steps 8 and 9.
End Of Sie
POWER STEERING FLUID INSPECTION
WM: POWER STEERING FLUID

id061400800500
Fluid Level Inspection 06-14
1. Inspect the power steering fluid level.
• Add fluid to the specified level as necessary.

Power steering fluid type

ATF-MIII, M-V or Dexron®II

Power steering fluid capacity (approximate quantity)

1.27 L {1.34 US qt, 1.11 lmp qt}

Fluid Leakage Inspection

1. Start the engine and let it idle.
2. Turn the steering wheel fully to the left and right to apply fluid pressure.

Caution
• If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid
temperature will rise excessively and adversely affect the oil pump.

3. Inspect for fluid leakage.

• If fluid leakage is found, replace related pipe
or hose.

Note
• The points where fluid leakage may occur
are indicated in the figure.

ac9uuw00001639

06-14–3
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POWER STEERING
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
2. Disconnect the pressure pipe from the steering 49 1232 670B
gear and linkage, and connect the SSTs.

Tightening torque
29.4—44.1 N·m {3.00—4.49 kgf·m, 21.7—32.5
ft·lbf} 49 H002 671

3. Bleed the air from the system. (See 06-14-3 AIR 49 G032 3A4A
BLEEDING.)
4. Open the gauge valve fully. PRESSURE
PIPE SIDE STEERING GEAR SIDE
5. Start the engine and turn the steering wheel fully
ac9uuw00001664
left and right to raise the fluid temperature to 50—
60 °C {122—140 °F}.
6. Close the gauge valve completely. GAUGE
7. Increase the engine speed to 1,000—1,500 rpm
and measure the fluid pressure generated by the CLOSE VALVE
oil pump. THERMOMETER COMPLETELY
50—60˚C
• If the pressure is not within the specification, {122—140˚F}
repair or replace the oil pump component.

Caution
• If the valve is left closed for more than 5
seconds, the fluid temperature will rise
excessively and adversely affect the oil
pump.
ac9uuw00002145

Oil pump fluid pressure

11.3—11.8 MPa {116—120 kgf/cm2, 1639—1711 psi}

8. Open the gauge valve fully and increase the GAUGE

engine speed to 1,000—1,500 rpm.
9. Turn the steering wheel fully to the left and right, OPEN VALVE
then measure the fluid pressure generated at the THERMOMETER COMPLETELY
50—60˚C
gear housing. {122—140˚F}
• If the pressure is not within the specification,
repair or replace the steering gear
component.

Caution
• If the steering wheel is kept in the fully
turned position for more than 5 seconds,
ac9uuw00002146
the fluid temperature will rise excessively
and adversely affect the oil pump.

Gear housing fluid pressure

11.3—11.8 MPa {116—120 kgf/cm2, 1639—1711 psi}

10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque.

Tightening torque
29.4—44.1 N·m {3.00—4.49 kgf·m, 21.7—32.5 ft·lbf}

11. Bleed the air from the system.

End Of Sie
WM: STEERING WHEEL AND COLUMN

06-14–4
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POWER STEERING
STEERING WHEEL AND COLUMN INSPECTION
id061400800300
Steering Wheel Play Inspection
1. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and verify that
the play is within the specification.
• If the play exceeds the specification, either the steering joints are worn or the backlash of the steering gear
is excessive. Correct as necessary.

Steering wheel play

0—30 mm {0—1.18 in}

Steering Wheel Looseness Inspection

1. Move the steering wheel as shown in the figure to
inspect for column bearing wear, steering shaft
joint play, steering wheel looseness, and column
looseness.
• Repair or replace as necessary.

06-14

ac9uuw00001917

Steering Wheel Effort Inspection

1. Inspect the following points:
• Tire size and tire pressure
• Fluid level
• Drive belt deflection
2. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position.
3. Remove the air bag module.

Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See
08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG SYSTEM SERVICE
CAUTIONS.)

4. Start the engine and warm the power steering fluid to 50—60 °C {122—140 °F}.
5. Measure the steering wheel effort using a torque
wrench.
• If not within the specification, verify the
following:
— No air in steering system
— No fluid leakage at hose or connectors
— Function of oil pump and steering gear

Steering wheel effort

7.8 N·m {80 kgf·cm, 58 in·lbf} max.

Note
• To determine whether the steering effort is
ac9uuw00001918

satisfactory or not, perform the inspection on

another vehicle of the same model and under the same conditions, and compare the results.
• The steering wheel effort varies with conditions as shown below.
— Road conditions, such as dry or wet, and asphalt or concrete.
— Tire conditions, such as brand, wear, and tire pressure.

End Of Sie

06-14–5
1890-1U-06H(06-14).fm 6 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION
id061400800400

Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See
08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG SYSTEM SERVICE
CAUTIONS.)

1. Remove the dashboard under cover (driver side). (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
2. Remove the column cover. (See 09-17-8 COLUMN COVER REMOVAL/INSTALLATION.)
3. Remove the coil antenna (with advanced keyless system). (See 09-14-19 COIL ANTENNA REMOVAL/
INSTALLATION [ADVANCED KEYLESS SYSTEM].)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. If the steering lock component of a vehicle equipped with the advanced keyless system is replaced, perform the
following procedure after installation.
• Without immobilizer system
— Steering lock unit programming (See 09-14-57 STEERING LOCK UNIT ID CODE REGISTRATION
[ADVANCED KEYLESS SYSTEM].)
• With immobilizer system
— Immobilizer system resetting (See 09-14-19 IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/
KEY ADDITION AND CLEARING [ADVANCED KEYLESS SYSTEM].) (See 09-14-37 IMMOBILIZER
SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND CLEARING [KEYLESS ENTRY
SYSTEM].)
8.8—12.8 N·m
{89.8—130.5 kgf·cm,
77.8—113.2 in·lbf} 1
3

2 39.2—49.0
{4.0—4.9, 30—36}
R

5 9
R

7
8

15.7—22.5
{1.7—2.2,
11.6—16.5} 11
10
4
18.6—26.5
{1.9—2.7,
14—19}
12

N·m {kgf·m, ft·lbf}

ac9uuw00001635

1 Air bag module 2 Locknut

(See 08-10-6 DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)

06-14–6
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POWER STEERING
3 Steering wheel 8 Dust cover
(See 06-14-7 Steering Wheel Removal Note.) 9 Steering lock mounting bolts
(See 06-14-8 Steering Wheel Installation Note.) (See 06-14-7 Steering Lock Mounting Bolts
4 Interlock cable Removal Note.)
(See 05-18-8 SELECTOR LEVER COMPONENT (See 06-14-8 Steering Lock Mounting Bolts
REMOVAL/INSTALLATION.) Installation Note.)
5 Combination switch 10 Steering lock component
(See 09-18-16 COMBINATION SWITCH 11 Key cylinder (Without advanced keyless system)
REMOVAL/INSTALLATION.) (See06-14-7 Key Cylinder (Without Advanced
6 Joint cover Keyless System) Removal Note.)
7 Steering shaft 12 Ignition switch
(See 06-14-7 Steering Shaft Removal Note.) (See 09-21-2 IGNITION SWITCH REMOVAL/
(See 06-14-8 Steering Shaft Installation Note.) INSTALLATION.)

Steering Wheel Removal Note

Caution
• Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will
collapse.
06-14
1. Set the vehicle in the straight-ahead position.
2. Remove the steering wheel using a suitable puller.

Steering Shaft Removal Note

Caution
• When removing/installing the steering shaft, protect the lower panel with a clean rag to prevent it
from being scratched by interference.

1. Protect the lower panel with a clean rag.

2. Remove the steering wheel using any commercially available puller.

Steering Lock Mounting Bolts Removal Note

1. Make a groove in the heads of the steering lock
mounting bolts using a chisel and a hammer.
2. Remove the bolts using a screwdriver.
3. Disassemble the steering lock component.

ac9uuw00001919

Key Cylinder (Without Advanced Keyless System) Removal Note

1. Turn the key to the ACC position.
2. Push the pin and remove the outer cylinder.

PIN

ac9uuw00001633

06-14–7
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POWER STEERING
Steering Lock Mounting Bolts Installation Note
1. Assemble the steering lock component to the steering shaft.
2. Verify that the lock operates correctly.
3. Install new steering lock mounting bolts.
4. Tighten the bolts until the heads break off.

ac9uuw00001920
Steering Shaft Installation Note
Caution
• Do not apply a shock in the axial direction of the shaft.
1. Lock the tilt lever.
2. Tighten nut A.
3. Tighten nut B.
4. Tighten bolt C.

ac9uuw00001634
Steering Wheel Installation Note
1. Make sure the wheels in the straight-ahead position, and install the steering wheel.
End Of Sie
STEERING SHAFT INSPECTION
WM: STEERING SHAFT

id061400800600
1. Inspect the following.
(1) Column bearing for damage
(2) Steering shaft length
• Replace the steering shaft component as
necessary.

Steering shaft length

211.6 mm {8.331 in}

ac9uuw00000134

2. Inspect the tilt operation.

(1) Verify that the adjusting lever moves smoothly
from unlock position to lock position.
(2) Verify that the steering shaft is fixed firmly
when the adjusting lever is locked.
• Replace the steering shaft component as
necessary. LOCKED
End Of Sie
WM: STEERING GEAR AND LINKAGE

ADJUSTING LEVER UNLOCKED

ac9uuw00000135

06-14–8
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POWER STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION
id061400800900

Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.

1. Drain the power steering fluid. (See 06-14-3 POWER STEERING FLUID INSPECTION.)
2. Remove the front under cover A and front under cover B. (See 09-16-18 FRONT UNDER COVER REMOVAL/
INSTALLATION.)
3. Remove the middle pipe. (See 01-15-1 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the transverse member. (See 02-13-15 TRANSVERSE MEMBER REMOVAL/INSTALLATION.)
5. Remove the front crossmember, steering gear and linkage component. (See 02-13-11 FRONT
CROSSMEMBER REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. After installation, adjust the total toe-in. (See 02-11-2 FRONT WHEEL ALIGNMENT.)
43.1—60.8
{4.40—6.19, 7.8—10.8 N·m
{80—110 kgf·cm, 43.1—60.8
06-14
31.8—44.8}
69.1—95.5 in·lbf} {4.40—6.19,
31.8—44.8}

2
1
96.9—136.0
{9.89—13.86, 96.9—136.0
71.5—100.3} {9.89—13.86,
71.5—100.3}

43.1—60.8
{4.40—6.19,
31.8—44.8}

43.1—60.8
{4.40—6.19,
31.8—44.8}

N·m {kgf·m, ft·lbf}

ac9uuw00001651

1 Insulator 3 Steering gear and linkage

2 Front stabilizer (See 06-14-10 Steering Gear and Linkage
Installation Note.)

06-14–9
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POWER STEERING
Steering Gear and Linkage Installation Note
1. Tighten the mounting bracket bolts to the
specified torque in the order shown.
2 1
Tightening torque
96.9—136.0 N·m {9.89—13.86 kgf·m, 71.5—
100.3 ft·lbf}

4 3

ac9uuw00001921

Bolt (Intermediate Shaft) Installation Note

1. Align the marks and install the intermediate shaft and bolt.
End Of Sie
STEERING GEAR AND LINKAGE DISASSEMBLY
id061400801000

Caution
• Place copper plates, rag, or similar material in a vise, when securing the mounting bracket portion
of the steering gear.

1. Disassemble in the order indicated in the table.

06-14–10
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POWER STEERING

18
19
2
14 3 21
15 20
16
17

22

26
SST
27 06-14
26
SST

25
SST SST SST
11 12 24
SST
23
9
7 10

8
6 13
5
4

ac9uuw00001854

1 Oil pipe 10 Tie rod

2 Return pipe (See 06-14-12 Lock Washer, Tie Rod Disassembly
Note.)
3 O-ring
11 Holder
4 Tie-rod end (See 06-14-12 Holder, Oil Seal (Holder Side)
(See 06-14-12 Tie-rod End Disassembly Note.) Disassembly Note.)
5 Locknut 12 Oil seal (holder side)
6 Boot clamp (See 06-14-12 Holder, Oil Seal (Holder Side)
7 Boot band Disassembly Note.)
8 Boot 13 O-ring
9 Lock washer 14 Locknut (adjusting cover)
(See 06-14-12 Lock Washer, Tie Rod Disassembly 15 Adjusting cover
Note.) (See 06-14-13 Adjusting Cover Disassembly Note.)

06-14–11
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POWER STEERING
16 Yoke spring 24 Oil seal (gear housing side)
17 Support yoke (See 06-14-13 Oil Seal (Gear Housing Side), Inner
Guide Disassembly Note.)
18 Clip
25 Inner guide
19 Pinion plug (See 06-14-13 Oil Seal (Gear Housing Side), Inner
20 Bolt Guide Disassembly Note.)
21 Pinion shaft component 26 Mounting rubber
22 O-ring (See 06-14-13 Mounting Rubber Disassembly
23 Steering rack Note.)
27 Gear housing

Tie-rod End Disassembly Note

1. Place alignment marks as shown in the figure for
proper installation.

MARK

ac9uuw00001855

Lock Washer, Tie Rod Disassembly Note

1. Unclamp the washer.
2. Lock the steering rack end against rotation with a
wrench and remove the tie rod. STEERING RACK
3. Remove the lock washer.

TIE ROD

ac9uuw00001856

Holder, Oil Seal (Holder Side) Disassembly Note

1. Remove the holder from the gear housing using
the SST.
49 L032 313

ac9uuw00001857

06-14–12
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POWER STEERING
2. Remove the oil seal from the holder using the
SST and a press.
49 G033 102

49 L032 314

ac9uuw00001858

Adjusting Cover Disassembly Note

1. Install two nuts to the bolt across a flat 24 mm
{0.94 in} and tighten them using a wrench. NUT
2. Disassemble the adjusting cover with the bolt and
nuts created in Step 1. BOLT

ACROSS FLAT 06-14

24 mm {0.94 in}

ac9uuw00001859

Oil Seal (Gear Housing Side), Inner Guide Disassembly Note

1. Set the SSTs as shown.
2. Insert the SSTs from the valve housing side.
3. Remove the oil seal (gear housing side) and inner
guide using a press.

49 F032 303

49 N032 319A

49 L032 314

ac9uuw00001860

Mounting Rubber Disassembly Note

1. Press the mounting rubber out from the gear housing using the SSTs and a press.
Substitution SST
• 49 B032 317
Outer diameter: 17.5—23 mm {0.7—0.9 in}
Length: 35 mm {1.4 in} or more 49 B032 317
• 49 T028 301
Outer diameter: 39—40 mm {1.54—1.57 in}
Inner diameter: 36—38 mm {1.42—1.49 in}
Length: 35 mm {1.4 in} or more
End Of Sie

49 T028 301
ac9uuw00001922

06-14–13
1890-1U-06H(06-14).fm 14 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
STEERING GEAR AND LINKAGE INSPECTION
id061400801100
Rack Inspection
1. Inspect the rack for cracking, damage, and tooth wear. Replace it if necessary.
2. Measure the runout of the rack.

Steering rack runout

Near point A: 0.15 mm {0.006 in} max.
Near point B: 0.20 mm {0.008 in} max.
B
3. If not within the specification, replace the rack.

ac9uuw00001861

Tie-rod End Inspection

1. Inspect the tie-rod end for damage and boot cracks. Replace it if necessary.
2. Inspect the ball joint for looseness. Replace the tie-rod end if necessary.
3. Rotate the ball joint five times.
4. Measure the rotation torque of the ball joint using
the SST and a pull scale.

Tie-rod end rotational torque

0.4—2.7 N·m {4.1—27.5 kgf·cm, 3.6—23.8
in·lbf}
49 0180 510B
[Pull scale reading: 3.4—25.5 N {0.35—2.60
kgf, 0.8—5.7 lbf}]

5. If not within the specification, replace the tie-rod

end.
ac9uuw00001862

Tie rod Inspection

1. Inspect the tie rod for bending and damage. Replace it if necessary.
2. Inspect the ball joint for looseness. Replace the tie rod if necessary.
3. Swing the tie rod five times.
4. Measure the swinging torque using a pull scale.

Tie-rod swing torque

0.1—4.0 N·m {1.1—40 kgf·cm, 0.89—35
in·lbf}
[Pull scale reading: 1.0—40.0 N {0.2—4.0
20 mm
kgf, 0.23—8.99 lbf}] {0.8 in}
90 mm
5. If not within the specification, replace the tie rod. {3.5 in}

End Of Sie

ac9uuw00001863

06-14–14
1890-1U-06H(06-14).fm 15 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
STEERING GEAR AND LINKAGE ASSEMBLY
id061400801200

Caution
• Place copper plates, rag, or similar material in a vise, when securing the mounting bracket portion
of the steering gear.

1. Assemble in the order indicated in the table.

27.5—39.2 19
{2.81—3.99,
20.3—28.9} 14
SEALANT 13 R
SST 10
40—58 {4.1—5.9, 30—42} 18 12
17 11 15.7—20.5 {1.61—2.09, 11.6—15.1}
GREASE

16
15
10—16
{1.1—1.6,
7—11} R
9

10—16 27 06-14
{1.1—1.6,
7—11}

SST 2
R
1
68.6—98.0
2 {7.00—9.99,
SST R 50.6—72.2}
R
R
78.4—98.0
R {8.00—9.99,
57.9—72.2}
GREASE

SST 4
58.9—73.5 SST
R R
{6.01—7.49, 43.5—54.2} 8 3
7 ATF

R ATF

R
R 20 ATF

23 21
5
68.6—98.0
{7.00—9.99, 22
R
50.6—72.2}
24 6
25
GREASE

26 78.4—98.0
{8.00—9.99,
57.9—72.2}

N·m {kgf·m, ft·lbf}

ac9uuw00001864

1 Gear housing 3 Oil seal (gear housing side)

2 Mounting rubber (See 06-14-17 Steering Rack, Oil Seal (Gear
(See 06-14-16 Mounting Rubber Assembly Note.) Housing Side), Inner Guide Assembly Note.)
4 Inner guide
(See 06-14-17 Steering Rack, Oil Seal (Gear
Housing Side), Inner Guide Assembly Note.)

06-14–15
1890-1U-06H(06-14).fm 16 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
5 Steering rack 17 Adjusting cover
(See 06-14-17 Steering Rack, Oil Seal (Gear (See 06-14-18 Adjusting Cover Assembly Note.)
Housing Side), Inner Guide Assembly Note.) 18 Locknut (adjusting cover)
6 O-ring (See 06-14-18 Adjusting Cover Assembly Note.)
7 Oil seal (holder side) 19 Clip
(See 06-14-18 Oil Seal (Holder Side) Assembly 20 Lock washer
Note.) (See 06-14-19 Lock Washer, Tie Rod Assembly
8 Holder Note.)
(See 06-14-18 Holder Assembly Note.) 21 Tie rod
9 O-ring (See 06-14-19 Lock Washer, Tie Rod Assembly
10 Pinion shaft component Note.)
11 Bolt 22 Boot
12 O-ring 23 Boot band
13 Return pipe 24 Boot clamp
14 Pinion plug 25 Locknut
15 Support yoke 26 Tie-rod end
16 Yoke spring 27 Oil pipe

Mounting Rubber Assembly Note

1. Apply soapy water to the rubber part of the mounting rubber.
2. Temporarily install the mounting rubber to the
steering gear so that the mounting rubber are in 17.0 mm 12.2 mm
the positions shown in the figure.
20˚ 20˚
12.2 mm
Caution
• If the mounting rubber is placed in the
wrong position or assembled in the
wrong direction, an installation
malfunction will result when the vehicle
is loaded. When assembling the
mounting rubber, verify the position and
directions.

15.5 mm 15.5 mm

ac9uuw00001865

06-14–16
1890-1U-06H(06-14).fm 17 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
3. Press the mounting rubber until the mounting
rubber end comes out completely from the gear
housing using the SSTs and a press.
Substitution SST 49 B032 317
• 49 B032 317
Outer diameter: 17.5—23 mm {0.7—0.9 in}
Length: 35 mm {1.4 in} or more
49 T028 301
• 49 T028 301
Outer diameter: 39—40 mm {1.54—1.57 in}
Inner diameter: 36—38 mm {1.42—1.49 in}
Length: 35 mm {1.4 in} or more

49 B032 317

06-14
49 T028 301

ac9uuw00001923

4. Reverse the gear housing, then press the MOUNTING RUBBER

mounting rubber until the mounting rubber end
comes out completely from the other side. At this
time, the mounting rubber end and steel pipe are
aligned. STEEL PIPE

49 B032 317 MOUNTING RUBBER END AND

STEEL PIPE ARE ALIGNED.

49 T028 301
ac9uuw00002147

Steering Rack, Oil Seal (Gear Housing Side), Inner Guide Assembly Note
1. Apply multi-purpose grease to the oil seal (gear housing side) and Inner guide.
2. Install the plastic bag to the steering rack teeth so
as not to damage the oil seal (gear housing side) OIL SEAL
and the inner guide, and install the oil seal (gear (GEAR HOUSING SIDE)
housing side) and the inner guide to the seal. INNER GUIDE
Move the oil seal (gear housing side) and the
inner guide together with the plastic bag so that
they pass the steering rack teeth, then remove the
plastic bag.
3. Put the steering rack into the gear housing.
4. Using a press, press-in the oil seal (gear housing
PLASTIC BAG
side) and inner guide until the press-in force
increases rapidly.
ac9uuw00001902

06-14–17
1890-1U-06H(06-14).fm 18 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
Oil Seal (Holder Side) Assembly Note
1. Assemble the oil seal (holder side) to the holder
using a press and the SST.

49 T028 203

ac9uuw00001866

Holder Assembly Note

1. Assemble the holder to the gear housing using
the SST.
2. Connect the SSTs to the power cylinder section 49 L032 313
of the gear housing.

ac9uuw00001867

3. Apply 53.3 kPa {400 mmHg, 15.7 inHg} vacuum

with a vacuum pump and verify that it is held for at
least 30 seconds.
4. If the vacuum is not held, replace the oil seal.

49 G032 3A1

ac9uuw00001868

Adjusting Cover Assembly Note

1. Set the rack to the center position.
2. Install two nuts to the bolt across a flat 24 mm {0.94 in} and tighten them using a wrench.
3. Assemble the adjusting cover with the bolt and
nuts created in Step 1. NUT
4. Tighten the adjusting cover to 19.6 N·m {2.0
kgf·m, 15 ft·lbf}. BOLT
5. Slide the rack back and forth 60 mm {2.4 in}
three times. ACROSS FLAT
6. Retighten the adjusting cover to 19.6 N·m {2.0 24 mm {0.94 in}
kgf·m, 15 ft·lbf}.

ac9uuw00001869

06-14–18
1890-1U-06H(06-14).fm 19 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
7. Loosen the adjusting cover 63° using the SST.
49 D032 316

ac9uuw00001870

8. Hold the adjusting cover so as not to rotate and

tighten the locknut.

Tightening torque
40.0—58.0 N·m {4.08—5.91 kgf·m, 29.5—42.7 49 0180 510B
ft·lbf}

9. Measure the pinion torque using the SST and pull 06-14
scale. (Measurement speed: 0.5—2.0 rpm)

Pinion shaft rotation torque

Center of rack ±90°: 1.0—1.6 N·m {1—16
ac9uuw00001871
kgf·cm, 8.9—14 in·lbf}
[Pull scale reading: 9—13 N {1.0—1.3 kgf,
2.1—2.9 lbf}]
Except center of rack ±90°: Less than 1.68 N·m {17.1kgf·cm, 14.8 in·lbf}
[Pull scale reading: Less than 13.8 N {1.4 kgf, 3.1 lbf}]

10. If not within the specification, repeat Step 4 to 9.

Lock Washer, Tie Rod Assembly Note

1. Temporary assemble the lock washer and the tie rod to the steering rack.
2. Lock the steering rack end against rotation with a
wrench and assemble the tie rod. STEERING RACK
3. Clamp the lock washer.
End Of Sie
WM: POWER STEERING OIL PUMP

TIE ROD

ac9uuw00001872

06-14–19
1890-1U-06H(06-14).fm 20 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
POWER STEERING OIL PUMP REMOVAL/INSTALLATION
id061400800700
1. Remove the windshield wiper arm and blade. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION.)
2. Remove the cowl grill. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
3. Remove the windshield wiper motor (See 09-19-4 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
4. Remove the cowl panel. (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
5. Remove the right side splashing shield.
6. Remove the drive belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-3.5].)
7. Remove in the order indicated in the table.
8. Install in the reserve order of removal.
7.8—10.8 N·m
{80—110 kgf·cm, 69.1—95.5 in·lbf}

6 8
4

29.4—44.1
{3.00—4.49,
21.7—32.5}

1
A
2

18.6—25.5 3 7
{1.90—2.60, 13.8—18.8} N·m {kgf·m, ft·lbf}
ac9uuw00001652
.

1 Pressure switch connector 6 Suction hose

2 Pressure pipe 7 Power steering pump
3 Bolts Power steering fluid tank
4 Suction hose clamp (Power steering fluid tank side) 8 (See 06-14-20 Power Steering Fluid Tank Removal
Note.)
5 Power steering pump and suction hose

Power Steering Fluid Tank Removal Note

1. Remove the coolant reserve tank with the hose COOLANT
still connected, and position the coolant reserve RESERVE TANK
tank out of the way.
End Of Sie POWER STEERING
FLUID TANK

ac9uuw00001653

06-14–20
1890-1U-06H(06-14).fm 21 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
POWER STEERING OIL PUMP DISASSEMBLY/ASSEMBLY
id061400800800

Note
• The following procedure is for replacement of the O-ring and oil seal only. Replace the pump component if
other repairs are necessary.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

15.35—20.05
{1.566—2.044,
11.33—14.78}

ATF

12

ATF
69.1—78.9
3 {7.05—8.04, 51.0—58.1}
14 9
2 06-14
10
16.7—22.5 R
{1.73—2.29,
12.4—16.5}
R 4
ATF
R ATF
11
ATF
5 R
6 1
13 SST
8 R ATF
ATF
15
ATF

16
7 R ATF
13.35—18.05
{1.362—1.840,
9.85—13.31}

19
18
R
ATF

SST
17

N·m {kgf·m, ft·lbf}

ac9uuw00002247
.

1 Power steering oil pump component 12 Cam ring

(See 06-14-22 Power Steering Oil Pump (See 06-14-23 Cam Ring Assembly Note.)
Component Disassembly Note.) 13 Rotor
2 Pressure switch component (See 06-14-23 Rotor Assembly Note.)
3 Pressure pipe fitting 14 Vane
4 O-ring 15 Side plate
5 Control valve (See 06-14-22 Side Plate Assembly Note.)
6 Spring 16 O-rings
7 Suction pipe 17 Shaft component
8 O-ring (See 06-14-22 Shaft Component Disassembly
Note.)
9 Rear pump body
(See 06-14-23 Rear Pump Body Assembly Note.) 18 Oil seal
(See 06-14-22 Oil Seal Assembly Note.)
10 Gasket
19 Front pump body
11 Clip

06-14–21
1890-1U-06H(06-14).fm 22 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
Power Steering Oil Pump Component Disassembly Note
1. Secure the power steering oil pump using the
SST.

Caution
• Use the SST to prevent damage to the 49 F032 301
pump when securing it in a vise.

ac9uuw00001847

Shaft Component Disassembly Note

1. Tap out the shaft component from the front pump
body using a plastic hammer.

ac9uuw00001848

Oil Seal Assembly Note

1. Install the oil seal in the front pump body using
the SST and plastic hammer.

49 F032 321

ac9uuw00001849

Side Plate Assembly Note

1. Install the side plate in the position shown in the
figure.

ac9uuw00001850

06-14–22
1890-1U-06H(06-14).fm 23 ページ ２００６年１２月１９日　火曜日　午後１２時４６分

POWER STEERING
Rotor Assembly Note
1. Install to the front pump body so that area B of the
groove is on the rear pump body side as shown in SEC. A-A
the figure. REAR PUMP BODY SIDE
AREA B

A A

FRONT PUMP BODY SIDE

ac9uuw00001851

Cam Ring Assembly Note

1. Install the cam ring in the front pump body with
the mark facing upward.

06-14

ac9uuw00001852

Rear Pump Body Assembly Note

1. After installing the rear body, manually turn the shaft to verify that it rotates smoothly.
End Of Sie

06-14–23
1890-1U-06H(06-50).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時５０分

TECHNICAL DATA
06-50 TECHNICAL DATA
STEERING TECHNICAL DATA. . . . . . . . 06-50–1

End of Toc
STEERING TECHNICAL DATA
WM: STEERING

id065000800200

Item Specification
Power steering fluid type ATF-MIII, M-V or Dexron®II
Power steering fluid capacity (approximate quantity) 1.27 L {1.34 US qt, 1.11 lmp qt}
Oil pump fluid pressure 11.3—11.8 MPa {116—120 kgf/cm2, 1639—1711 psi}
Gear housing fluid pressure 11.3—11.8 MPa {116—120 kgf/cm2, 1639—1711 psi}
Steering wheel play 0—30 mm {0—1.18 in}
Steering wheel effort 7.8 N·m {80 kgf·cm, 58 in·lbf} max.
Steering shaft length 211.6 mm {8.331 in}
Near point A: 0.15 mm {0.006 in} max.
Steering rack runout
Near point B: 0.20 mm {0.008 in} max.
0.4—2.7 N·m {4.1—27.5 kgf·cm, 3.6—23.8 in·lbf} 06-50
Tie-rod end rotational torque
[Pull scale reading: 3.4—25.5 N {0.35—2.60 kgf, 0.8—5.7 lbf}]
0.1—4.0 N·m {1.1—40 kgf·cm, 0.89—35 in·lbf}
Tie-rod swing torque
[Pull scale reading: 1.0—40.0 N {0.2—4.0 kgf, 0.23—8.99 lbf}]
Center of rack ±90°: 1.0—1.6 N·m {1—16 kgf·cm, 8.9—14 in·lbf}
[Pull scale reading: 9—13 N {1.0—1.3 kgf, 2.1—2.9 lbf}]
Pinion shaft rotation torque Except center of rack ±90°: Less than 1.68 N·m {17.1kgf·cm, 14.8
in·lbf}
[Pull scale reading: Less than 13.8 N {1.4 kgf, 3.1 lbf}]

End Of Sie

06-50–1
1890-1U-06H(06-60).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時５１分

SERVICE TOOLS
06-60 SERVICE TOOLS
STEERING SST. . . . . . . . . . . . . . . . . . . . 06-60–1

End of Toc
STEERING SST
WM: STEERING

id066000800100

49 1232 670B 49 H002 671 49 G032 3A4A

Power steering Adapter Power steering

gauge set gauge adapter
set
49 B032 317 49 F032 303 49 L032 314

Bearing and oil Handle Remover

seal remover

49 N032 319A 49 G033 102 49 F032 321

Support plate Handle Installer B 06-60

49 T028 301 49 T028 203 49 L032 313

Dust boot Installer Rubber Wrench

installer bush

49 D032 316 49 0180 510B 49 G032 3A1

Protractor Preload Joint hose set

measuring
attachment
49 F032 301

Power steering
pump hanger —
—

End Of Sie

06-60–1
1890-1U-06H(07-02).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

HEATER, VENTILATION &

AIR CONDITIONING (HVAC)
07SECTION

Toc of SCT
ON-BOARD DIAGNOSTIC . . . . 07-02 BASIC SYSTEM . . . . . . . . . . . . 07-11
SYMPTOM CONTROL SYSTEM . . . . . . . . 07-40
TROUBLESHOOTING . . . . . . 07-03 TECHNICAL DATA . . . . . . . . . . 07-50
REFRIGERANT SYSTEM . . . . . 07-10 SERVICE TOOLS . . . . . . . . . . . 07-60
Toc of SCT
07-02 ON-BOARD DIAGNOSTIC
HVAC SYSTEM WIRING DIAGRAM . . . . 07-02–2 DTC 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–18
DIAGNOSTIC TROUBLE DTC 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–19
CODE NUMBER INSPECTION . . . . . . . 07-02–3 DTC 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–20
Present Failure Indication Mode . . . . . . 07-02–4 DTC 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–21
Past Failure Indication Mode . . . . . . . . . 07-02–4 DTC 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–22 07-02
Erasing Past Failure Memory . . . . . . . . 07-02–4 DTC 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–23
DTC Table . . . . . . . . . . . . . . . . . . . . . . . 07-02–4 DTC 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–24
Output Device Operation DTC 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–25
Check Mode . . . . . . . . . . . . . . . . . . . . 07-02–6 DTC 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–26
DTC 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–9 DTC 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–26
DTC 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–10 DTC 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–27
DTC 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–11 DTC 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–28
DTC 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–12 DTC 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–29
DTC 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–13 DTC 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–30
DTC 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–14 DTC 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–31
DTC 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–15 DTC 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–32
DTC 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–16 DTC 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–33
DTC 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–17 DTC 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07-02–34

End of Toc
WM: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)

07-02–1
1890-1U-06H(07-02).fm 2 ページ ２００６年１２月２０日　水曜日　午前９時４７分

ON-BOARD DIAGNOSTIC
HVAC SYSTEM WIRING DIAGRAM
id070200800100
Front
A/C RELAY

IG2
BCM
MAGNETIC
PCM CLUTCH
FRONT CLIMATE CONTROL UNIT
1W 1B
1S

CHECK 5V REFRIGERANT PRESSURE

1U
CONNECTOR SWITCH
5V 2B
2E
FRONT AIRFLOW
B MODE ACTUATOR
1J M
AMBIENT TEMPERATURE
1H
SENSOR
2I
CABIN TEMPERATURE
SENSOR 2F DRIVER-SIDE
2K FRONT AIR MIX ACTUATOR
1F M
FRONT EVAPORATOR
1A
TEMPERATURE SENSOR
2H

2P 2G PASSENGER-SIDE
SOLAR RADIATION FRONT AIR MIX ACTUATOR
A SENSOR 1C M
LH 1E
2M
RH CPU A
B
2O

1O
TNS RELAY 3D
1M AIR INTAKE ACTUATOR
1X
M IG2

INFORMATION
2C
DISPLAY FRONT BLOWER RELAY
M FRONT BLOWER MOTOR
INSTRUMENT
2A
CLUSTER 1P
REAR
FRONT POWER MOS FET
WINDOW 1Q 1R
DEFROSTER
RELAY
1D
SEAT WARMER
RELAY 1K

ac9uuw00002368

07-02–2
1890-1U-06H(07-02).fm 3 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
Rear

BCM
IG2

FRONT CLIMATE CONTROL UNIT

1W 1B

C
5V
5V
REAR EVAPORATOR
TEMPERATURE SENSOR
2B
2J
2D REAR AIRFLOW
2P
MODE ACTUATOR
1N M
1L

A 3E
2N REAR AIR MIX
C 3G ACTUATOR
1G M
J 3C CPU 1I
REAR CLIMATE G 3I
CONTROL UNIT
C 07-02
B 3F
REAR BLOWER RELAY
F 3H
M REAR BLOWER MOTOR
D 3J 1T

REAR POWER MOS FET

1V

INSTRUMENT
CLUSTER

ac9uuw00002459

End Of Sie
DIAGNOSTIC TROUBLE CODE NUMBER INSPECTION
id070200802000
1. Remove the dashboard under cover (passenger side). (See 09-17-14 DASHBOARD UNDER COVER
REMOVAL/INSTALLATION.)
2. Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
3. Short the check connector terminal A to the CHECK
ground using a jumper wire. CONNECTOR
4. Shine a 60 W incandescent light from a height of
approx. 100 mm {3.9 in} onto the solar radiation
sensor. FUSE
BLOCK
Note
• When incandescent light does not shine on
the solar radiation sensor, the climate control
unit determines a malfunction and indicates
a diagnostic trouble code “02, 04”.

5. Turn the ignition switch to ON position. JUMPER WIRE

6. Read DTCs on the information display. Carry out GROUND
DTC inspection. (present and past failure
indication modes)
• When the system is normal, “00” will be CHECK CONNECTOR
indicated on the display.
• If any of the diagnostic trouble codes are A
indicated, carry out troubleshooting according
to the code.
7. After completion of repairs, erase all diagnostic
trouble code(s) from memory. (See 07-02-4
Erasing Past Failure Memory.) ac9uuw00001151
8. Remove the jumper wire.

07-02–3
1890-1U-06H(07-02).fm 4 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
Present Failure Indication Mode
• The on-board diagnostic function display the present failure indication mode directly after start up. In present
failure indication mode, present failures in the control system circuits (open, short circuits) are detected, and
the DTCs are indicated on the information display.
— If a diagnostic trouble code is indicated, refer to the following diagnostic trouble code table and inspect the
appropriate system.

Past Failure Indication Mode

• While in present failure indication mode, press the
A/C switch to change to the past failure indication
A/C SWITCH
mode. In past failure indication mode, past
failures (intermittent problems) in the input sensor
circuits (open, short circuits) are shorted, and the
DTCs are indicated on the information display.
— If a diagnostic trouble code is indicated, refer
to the following diagnostic trouble code table
and inspect the appropriate system.
(Disconnections and short circuits are
memorized in the same system even if either
occurs only once.)
ac9uuw00002297
— If the A/C switch is pressed again while in
past failure indication mode, the on-board
diagnostic function will return to present failure indication mode.

Erasing Past Failure Memory

• When DTCs are displayed in the past failure
indication mode, they remain in the memory after AUTO SWITCH
the failed systems are corrected. Consequently,
the next time the past failure indication mode is
used, the same past failure DTCs will be indicated
on the information display. Therefore, erase the
past failure memory after correcting all failed
systems. To clear the past malfunction memory,
press the AUTO and REC switches on the front
climate control unit at the same time. Then "01" is
displayed. If cleared, "00" will be indicated. REC SWITCH

ac9uuw00000942

DTC Table
Output Memory
No. Malfunction location Detected condition Page
pattern function
Solar radiation sensor (RH) circuit short (See 07-02-9
02 -
DTC 02.)
Solar radiation sensor
(present malfunction) Solar radiation sensor (LH) circuit short (See 07-02-10
04 -
DTC 04.)
Cabin temperature Cabin temperature sensor circuit open/short
(See 07-02-11
06 sensor (present circuit -
DTC 06.)
malfunction)
When an open/short has occured in the cabin
Cabin temperature (See 07-02-12
07 temperature sensor circuit 1 time or more in X
sensor (past malfunction) DTC 07.)
the past
Front evaporator Front evaporator temperature sensor circuit
(See 07-02-13
10 temperature sensor open/short circuit -
DTC 10.)
(present malfunction)
Front evaporator When an open/short has occured in the front
(See 07-02-14
11 temperature sensor (past evaporator temperature sensor circuit 1 time X
DTC 11.)
malfunction) or more in the past
Front ambient Front ambient temperature sensor circuit open/
(See 07-02-15
12 temperature sensor short circuit -
DTC 12.)
(present malfunction)

07-02–4
1890-1U-06H(07-02).fm 5 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
Output Memory
No. Malfunction location Detected condition Page
pattern function
When an open/short has occured in the
Ambient temperature (See 07-02-16
13 ambient temperature sensor circuit 1 time or X
sensor (past malfunction) DTC 13.)
more in the past
Driver-side front air mix Driver-side front air mix actuator
(See 07-02-17
18 actuator (potentiometer) (potentiometer) circuit open/short circuit -
DTC 18.)
(present malfunction)
Driver-side front air mix When an open/short has occured in the driver-
(See 07-02-18
19 actuator (potentiometer) side front air mix actuator (potentiometer) X
DTC 19.)
(past malfunction) circuit 1 time or more in the past
Front airflow mode Front airflow mode actuator (potentiometer)
(See 07-02-19
21 actuator (potentiometer) circuit open/short circuit -
DTC 21.)
(present malfunction)
Front airflow mode When an open/short has occured in the front
(See 07-02-20
22 actuator (potentiometer) airflow mode actuator (potentiometer) circuit 1 X
DTC 22.)
(past malfunction) time or more in the past
Passenger-side front air Passenger- side front air mix actuator
mix actuator (potentiometer) circuit open/short circuit (See 07-02-21
37 -
(potentiometer) (present DTC 37.)
malfunction)
Passenger-side front air When an open/short has occured in the
mix actuator passenger-side front air mix actuator (See 07-02-22
38 X
(potentiometer) (past (potentiometer) circuit 1 time or more in the DTC 38.)
malfunction) past
07-02
Driver-side front air mix When motor lock has occured in the driver-side
(See 07-02-23
58 actuator (motor lock) front air mix actuator circuit 1 time or more in X
DTC 58.)
(past malfunction) the past
Front airflow mode When motor lock has occured in the front
(See 07-02-24
59 actuator (motor lock) airflow mode actuator circuit 1 time or more in X
DTC 59.)
(past malfunction) the past
Passenger-side front air When motor lock has occured in the
(See 07-02-25
61 mix actuator (motor lock) passenger-side front air mix actuator circuit 1 X
DTC 61.)
(past malfunction) time or more in the past
Rear climate control unit Between front climate control unit and rear
set airflow volume climate control unit set airflow volume (See 07-02-26
74 -
communication system communication circuit open/short circuit DTC 74.)
(present malfunction)
Rear climate control unit Between front climate control unit and rear
set temperature climate control unit set temperature (See 07-02-26
75 -
communication system communication circuit open/short circuit DTC 75.)
(present malfunction)
Rear air mix actuator Rear air mix actuator (potentiometer) circuit
(See 07-02-27
76 (potentiometer) (present open/short circuit -
DTC 76.)
malfunction)
Rear air mix actuator When an open/short has occured in the rear air
(See 07-02-28
77 (potentiometer) (past mix actuator (potentiometer) circuit 1 time or X
DTC 77.)
malfunction) more in the past
Rear evaporator Rear evaporator temperature sensor circuit
(See 07-02-29
78 temperature sensor open/short circuit -
DTC 78.)
(present malfunction)
Rear evaporator When an open/short has occured in the rear
(See 07-02-30
79 temperature sensor (past evaporator temperature sensor circuit 1 time X
DTC 79.)
malfunction) or more in the past
Rear airflow mode Rear airflow mode actuator (potentiometer)
(See 07-02-31
85 actuator (potentiometer) circuit open/short circuit -
DTC 85.)
(present malfunction)
Rear airflow mode When an open/short has occured in the rear
(See 07-02-32
86 actuator (potentiometer) airflow mode actuator (potentiometer) circuit 1 X
DTC 86.)
(past malfunction) time or more in the past
Rear air mix actuator When motor lock has occured in the rear air
(See 07-02-33
95 (motor lock) (past mix actuator circuit 1 time or more in the past X
DTC 95.)
malfunction)
Rear airflow mode When motor lock has occured in the rear
(See 07-02-34
96 actuator (motor lock) airflow mode actuator circuit 1 time or more in X
DTC 96.)
(past malfunction) the past

07-02–5
1890-1U-06H(07-02).fm 6 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
Output Device Operation Check Mode
Inspection
1. Warm up the engine.
2. Turn the ignition switch to LOCK position.
3. Remove the dashboard under cover (passenger side). (See 09-17-14 DASHBOARD UNDER COVER
REMOVAL/INSTALLATION.)
4. Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
5. Short the check connector terminal A to the CHECK
ground using a jumper wire. CONNECTOR
6. Shine a 60 W incandescent light from a height of
approx. 100 mm {3.9 in} onto the solar radiation
sensor. FUSE
BLOCK
Note
• When incandescent light does not shine on
the solar radiation sensor, the climate control
unit determines a malfunction and indicates
a diagnostic trouble code “02, 04”.

7. Start the engine. JUMPER WIRE

GROUND

CHECK CONNECTOR

ac9uuw00001151

8. Press the AUTO switch.

9. Verify the operation of the each output device AUTO SWITCH
when changing steps by pressing the REC switch,
and referring to the output device operation check
chart.
• If not as specified, inspect the malfunctioning
system.

Note
• If the AUTO switch is pressed again, the on-
board diagnostic function will return to REC SWITCH
present failure indication mode.
ac9uuw00000942

10. Turn the ignition switch to LOCK position to end

the output device operation check mode.

07-02–6
1890-1U-06H(07-02).fm 7 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
Output device operation check table
Operating
Step
device
Operating conditions Monitor* Output to information display
1 Front climate • Entire illumination of climate
control unit control display

Entire
illuminati
on of
climate
Information control
display display

2 Blower motor FRONT • The front A/C airflow volume is

speed displayed in the front airflow
7TH volume display area.
6TH
5TH
4TH
3RD
07-02
2ND
1ST
OFF

REAR 01

15TH
13TH
11TH
8TH

6TH
3RD
1ST
OFF

3 Air mix actuator FRONT/REAR 21.0 • The display is the same as the
operation (100%) set temperature display
20.5
100% 100% (50%)

50% 50% 50% 50%

20.0
(0%)
0% 0%

07-02–7
1890-1U-06H(07-02).fm 8 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
Operating
Step
device
Operating conditions Monitor* Output to information display
4 Airflow mode FRONT • The front A/C airflow mode is
actuator displayed in the front mode
operation display area.
VENT — The DEFROSTER switch
indicator illuminates during
BI-LEVEL
DEFROSTER mode.
HEAT • The rear A/C airflow mode
HEAT/DEF
cannot be displayed.
DEFROSTER

03
REAR

VENT
BI-LEVEL

HEAT

5 Air intake • The intake mode is displayed in

actuator the intake mode display area.
operation FRESH FRESH FRESH FRESH — The REC switch indicator
REC REC REC REC illuminates during REC
mode.
• "A/C" is displayed when the A/
C is on.The A/C switch
04 indicator illuminates during A/C
ON.
A/C compressor
operation
ON ON

OFF OFF

*
: Shown on the information display according to step.

End Of Sie

07-02–8
1890-1U-06H(07-02).fm 9 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 02
id070200802100

DTC 02 Solar radiation sensor (RH) (present)

POSSIBLE • Solar radiation sensor malfunction
CAUSE • Open or short circuit between solar radiation sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect solar radiation sensor. (See 07-40-17 Yes Go to the next step.
SOLAR RADIATION SENSOR No Replace solar radiation sensor. (See 07-40-17 SOLAR
INSPECTION.) RADIATION SENSOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect climate control unit connector Yes Repair wiring harness.
(16-pin) and solar radiation sensor No Go to the next step.
connector.
• Is there continuity between following
terminals of front climate control unit
connector (16-pin) and terminal solar
radiation sensor connector?
— 2O—B
— 2B—A
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2O of front climate control unit No Inspect the connection of the front climate control unit
connector (16-pin) and terminal B of solar connector. 07-02
radiation sensor connector?
FRONT CLIMATE CONTROL UNIT CONNECTOR
SOLAR RADIATION SENSOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A C B A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–9
1890-1U-06H(07-02).fm 10 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 04
id070200802200

DTC 04 Solar radiation sensor (LH) (present)

POSSIBLE • Solar radiation sensor malfunction
CAUSE • Open or short circuit between solar radiation sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect solar radiation sensor. (See 07-40-17 Yes Go to the next step.
SOLAR RADIATION SENSOR No Replace solar radiation sensor. (See 07-40-17 SOLAR
INSPECTION.) RADIATION SENSOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and solar radiation sensor No Go to the next step.
connector.
• Is there continuity between following
terminals of front climate control unit
connector (16-pin) and terminal solar
radiation sensor connector?
— 2M—C
— 2B—A
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2M of front climate control unit No Inspect the connection of the front climate control unit
connector (16-pin) and terminal C of solar connector.
radiation sensor connector?
FRONT CLIMATE CONTROL UNIT CONNECTOR
SOLAR RADIATION SENSOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A C B A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–10
1890-1U-06H(07-02).fm 11 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 06
id070200802300

DTC 06 Cabin temperature sensor (present)

POSSIBLE • Cabin temperature sensor malfunction
CAUSE • Open or short circuit between cabin temperature sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Is resistance between terminals 2K and 2P Yes Inspect the connection of the front climate control unit
of front climate control unit connector (16- connector.
pin) as indicated below? No Go to the next step.
— 190 ohms—40 kilohms (-30—80 °C {-
22—176 °F})
— 1.615—1.785 kilohms (25 °C {77 °F})
2 • Inspect cabin temperature sensor. (See 07- Yes Repair wiring harness.
40-19 CABIN TEMPERATURE SENSOR No Replace cabin temperature sensor. (See 07-40-19 CABIN
INSPECTION.) TEMPERATURE SENSOR REMOVAL/INSTALLATION.)
• Is it okay?
FRONT CLIMATE CONTROL UNIT CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A
2P 2N 2L 2J 2H 2F 2D 2B 07-02

End Of Sie

07-02–11
1890-1U-06H(07-02).fm 12 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 07
id070200802400

DTC 07 Cabin temperature sensor (past)

POSSIBLE • Cabin temperature sensor malfunction
CAUSE • Open or short circuit between cabin temperature sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect cabin temperature sensor. (See 07- Yes Go to the next step.
40-19 CABIN TEMPERATURE SENSOR No Replace cabin temperature sensor. (See 07-40-19 CABIN
INSPECTION.) TEMPERATURE SENSOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and cabin temperature No Go to the next step.
sensor connector.
• Is there open circuit between the following
terminals of front climate control unit
connector (16-pin) and cabin temperature
sensor connector?
— 2K—B
— 2P—A
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2K of front climate control unit No Connect front climate control unit connector, then go to the
connector (16-pin) and B of cabin next step.
temperature sensor connector?
4 • Turn the ignition switch to ON position. Yes This system is normal at present. (Erase the past failure
• Measure voltage at terminal the following from memory.)
terminal 2K of front climate control unit No inspect the connection of the front climate control unit
connector (16-pin). connector.
• Is voltage approx. 5V?
FRONT CLIMATE CONTROL UNIT CONNECTOR
CABIN TEMPERATURE SENSOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A B A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–12
1890-1U-06H(07-02).fm 13 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 10
id070200802500

DTC 10 Front evaporator temperature sensor (present)

POSSIBLE • Front evaporator temperature sensor malfunction
CAUSE • Open or short circuit between front evaporator temperature sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Is resistance between terminals 2H and 2P Yes Inspect the connection of the front climate control unit
of front climate control unit connector (16- connector.
pin) as indicated below? No Go to the next step.
— 166 ohms—32 kilohms (-30—80 °C {-
22—176 °F})
— 2.248—2.436 kilohms (15 °C {59 °F})
2 • Inspect front evaporator temperature sensor. Yes Repair wiring harness.
(See 07-40-20 FRONT EVAPORATOR No Replace front evaporator temperature sensor. (See 07-40-
TEMPERATURE SENSOR INSPECTION.) 19 FRONT EVAPORATOR TEMPERATURE SENSOR
• Is it okay? REMOVAL/INSTALLATION.)
FRONT CLIMATE CONTROL UNIT CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A
2P 2N 2L 2J 2H 2F 2D 2B 07-02

End Of Sie

07-02–13
1890-1U-06H(07-02).fm 14 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 11
id070200802600

DTC 11 Front evaporator temperature sensor (past)

POSSIBLE • Front evaporator temperature sensor malfunction
CAUSE • Open or short circuit between front evaporator temperature sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect front evaporator temperature sensor. Yes Go to the next step.
(See 07-40-20 FRONT EVAPORATOR No Replace front evaporator temperature sensor. (See 07-40-
TEMPERATURE SENSOR INSPECTION.) 19 FRONT EVAPORATOR TEMPERATURE SENSOR
• Is it okay? REMOVAL/INSTALLATION.)
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and front evaporator No Go to the next step.
temperature sensor connector.
• Is there open circuit between following
terminals of front climate control unit
connector (16-pin) and front evaporator
temperature sensor connector?
— 2H—B
— 2P—A
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2H of front climate control unit No Connect front climate control unit connector, then go to the
connector (16-pin) and terminal B of front next step.
evaporator temperature sensor connector?
4 • Turn ignition switch to ON position. Yes This system is normal at present. (Erase the past failure
• Measure voltage at terminal 2H of front from memory.)
climate control unit connector (16-pin). No Inspect the connection of the front climate control unit
• Is voltage approx. 5 V? connector.
FRONT CLIMATE CONTROL UNIT CONNECTOR
FRONT EVAPORATOR
TEMPERATURE SENSOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A B A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–14
1890-1U-06H(07-02).fm 15 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 12
id070200802700

DTC 12 Ambient temperature sensor (present)

POSSIBLE • Ambient temperature sensor malfunction
CAUSE • Open or short circuit between ambient temperature sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Is resistance between terminals 2I and 2P of Yes Inspect the connection of the front climate control unit
front climate control unit connector (16-pin) connector.
as indicated below? No Go to the next step.
— 190 ohms—40 kilohms (-30—80 °C {-
22—176 °F})
— 1.615—1.785 kilohms (25 °C {77 °F})
2 • Inspect ambient temperature sensor. (See Yes Repair wiring harness.
07-40-18 AMBIENT TEMPERATURE No Replace ambient temperature sensor. (See 07-40-18
SENSOR INSPECTION.) AMBIENT TEMPERATURE SENSOR REMOVAL/
• Is it okay? INSTALLATION.)
FRONT CLIMATE CONTROL UNIT CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A
2P 2N 2L 2J 2H 2F 2D 2B 07-02

End Of Sie

07-02–15
1890-1U-06H(07-02).fm 16 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 13
id070200802800

DTC 13 Ambient temperature sensor (past)

POSSIBLE • Ambient temperature sensor malfunction
CAUSE • Open or short circuit between ambient temperature sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect ambient temperature sensor. (See Yes Go to the next step.
07-40-18 AMBIENT TEMPERATURE No Replace ambient temperature sensor. (See 07-40-18
SENSOR INSPECTION.) AMBIENT TEMPERATURE SENSOR REMOVAL/
• Is it okay? INSTALLATION.)
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and ambient temperature No Go to the next step.
sensor connector.
• Is there open circuit between following
terminals of front climate control unit
connector (16-pin) and ambient temperature
sensor connector?
— 2I—B
— 2P—A
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2I of front climate control unit No Connect front climate control unit connector, then go to the
connector (16-pin) and terminal B of ambient next step.
temperature sensor connector?
4 • Turn ignition switch to ON position. Yes This system is normal at present. (Erase the past failure
• Measure voltage at terminal 2I of front from memory.)
climate control unit connector (16-pin). No Inspect the connection of the front climate control unit
• Is voltage approx. 5 V? connector.
AMBIENT TEMPERATURE
FRONT CLIMATE CONTROL UNIT CONNECTOR
SENSOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A B A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–16
1890-1U-06H(07-02).fm 17 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 18
id070200803100

DTC 18 Driver-side front air mix actuator (potentiometer) (present)

• Driver-side front air mix actuator malfunction
POSSIBLE • Open circuit between driver-side front air mix actuator and front climate control unit
CAUSE • Short circuit between driver-side front air mix actuator (terminal E) and front climate control unit
(terminal 2F: 16-pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect driver-side front air mix actuator. Yes Go to the next step.
(See 07-40-10 FRONT AIRFLOW MODE No Replace driver-side front air mix actuator. (See 07-40-5
ACTUATOR INSPECTION.) FRONT AIR MIX ACTUATOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect passenger side front air mix Yes Go to the next step.
actuator connector. No Repair wiring harness. (Short circuit)
• Disconnect front airflow mode actuator
connector.
• Disconnect rear air mix actuator connector.
• Disconnect rear airflow mode actuator
connector.
• Disconnect ambient temperature sensor
connector.
• Disconnect cabin temperature sensor
connector. 07-02
• Disconnect front and rear evaporator
temperature sensor connector.
• Is resistance between terminals 2F and 2P of
front climate control unit connector (16-pin)
more than 840 ohms?
3 • Disconnect front climate control unit Yes Go to the next step.
connector (16-pin). No Repair wiring harness. (Open circuit)
• Is resistance between terminals 2B and 2P
of front climate control unit connector (16-
pin) less than 7.8 kilohms?
4 • Is resistance between terminals 2B and 2F of Yes Inspect the connection of the front climate control unit
front climate control unit connector (24-pin) connector.
less than 6.24 kilohms? No Repair wiring harness. (Open circuit)
FRONT CLIMATE CONTROL UNIT CONNECTOR INSTRUMENT CLUSTER CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–17
1890-1U-06H(07-02).fm 18 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 19
id070200803200

DTC 19 Driver-side front air mix actuator (potentiometer) (past)

• Driver-side front air mix actuator malfunction
POSSIBLE • Open circuit between driver-side front air mix actuator and front climate control unit
CAUSE • Short circuit between driver-side front air mix actuator (terminal E) and front climate control unit
(terminal 2F: 16-pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect driver-side front air mix actuator. Yes Go to the next step.
(See 07-40-6 FRONT AIR MIX ACTUATOR No Replace driver-side front air mix actuator. (See 07-40-5
INSPECTION.) FRONT AIR MIX ACTUATOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and driver-side front air No Go to the next step.
mix actuator connector.
• Is there open circuit between following
terminals of front climate control unit
connector (16-pin) and driver-side front air
mix actuator connector?
— 2F—E
— 2B—A
— 2P—C
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2F of front climate control unit No This system is normal at present. (Erase the past failure
connector (16-pin) and terminal E of driver- from memory.)
side front air mix actuator connector?
FRONT CLIMATE CONTROL UNIT CONNECTOR DRIVER-SIDE FRONT AIR MIX
ACTUATOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A
G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–18
1890-1U-06H(07-02).fm 19 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 21
id070200803300

DTC 21 Front airflow mode actuator (potentiometer) (present)

• Front airflow mode actuator malfunction
POSSIBLE • Open circuit between front airflow mode actuator and front climate control unit
CAUSE • Short circuit between front airflow mode actuator (terminal E) and front climate control unit (terminal 2E:
16-pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect front airflow mode actuator. (See 07- Yes Go to the next step.
40-11 REAR AIRFLOW MODE ACTUATOR No Replace front airflow mode actuator. (See 07-40-9 FRONT
INSPECTION.) AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect driver side and passenger side Yes Go to the next step.
front air mix actuator connector. No Repair wiring harness. (Short circuit)
• Disconnect rear air mix actuator connector.
• Disconnect rear airflow mode actuator
connector.
• Disconnect ambient temperature sensor
connector.
• Disconnect cabin temperature sensor
connector.
• Disconnect front and rear evaporator
temperature sensor connector. 07-02
• Is resistance between terminals 2E and 2P
of front climate control unit connector (16-
pin) more than 840 ohms?
3 • Disconnect front climate control unit Yes Go to the next step.
connector (16-pin). No Repair wiring harness. (Open circuit)
• Is resistance between terminals 2B and 2P
of front climate control unit connector (16-
pin) less than 7.8 kilohms?
4 • Is resistance between terminals 2B and 2E Yes Inspect the connection of the front climate control unit
of front climate control unit connector (16- connector.
pin) less than 6.24 kilohms? No Repair wiring harness. (Open circuit)

FRONT CLIMATE CONTROL UNIT CONNECTOR FRONT AIRFLOW MODE

ACTUATOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–19
1890-1U-06H(07-02).fm 20 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 22
id070200803400

DTC 22 Front airflow mode actuator (potentiometer) (past)

• Front airflow mode actuator malfunction
POSSIBLE • Open circuit between front airflow mode actuator and front climate control unit
CAUSE • Short circuit between front airflow mode actuator (terminal E) and front climate control unit (terminal 2E:
16-pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect front airflow mode actuator. (See 07- Yes Go to the next step.
40-10 FRONT AIRFLOW MODE ACTUATOR No Replace front airflow mode actuator. (See 07-40-9 FRONT
INSPECTION.) AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and front airflow mode No Go to the next step.
actuator connector.
• Is there open circuit between following
terminals of front climate control unit
connector (16-pin) and front airflow mode
actuator connector?
— 2B—A
— 2E—E
— 2P—C
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2E of front climate control unit No This system is normal at present. (Erase the past failure
connector (16-pin) and terminal E of front from memory.)
airflow mode actuator connector?
FRONT CLIMATE CONTROL UNIT CONNECTOR
FRONT AIRFLOW MODE
ACTUATOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A
G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–20
1890-1U-06H(07-02).fm 21 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 37
id070200803500

DTC 37 Passenger-side front air mix actuator (potentiometer) (present)

• Passenger-side front air mix actuator malfunction
POSSIBLE • Open circuit between passenger-side front air mix actuator and front climate control unit
CAUSE • Short circuit between passenger-side front air mix actuator (terminal E) and front climate control unit
(terminal 2G: 16-pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect passenger-side front air mix actuator. Yes Go to the next step.
(See 07-40-6 FRONT AIR MIX ACTUATOR No Replace passenger-side front air mix actuator. (See 07-40-5
INSPECTION.) FRONT AIR MIX ACTUATOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect driver side front air mix actuator Yes Go to the next step.
connector. No Repair wiring harness. (Short circuit)
• Disconnect front airflow mode actuator
connector.
• Disconnect rear air mix actuator connector.
• Disconnect rear airflow mode actuator
connector.
• Disconnect ambient temperature sensor
connector.
• Disconnect cabin temperature sensor
connector. 07-02
• Disconnect front and rear evaporator
temperature sensor connector.
• Is resistance between terminals 2G and 2P
of front climate control unit connector (16-
pin) more than 840 ohms?
3 • Disconnect front climate control unit Yes Go to the next step.
connector (16-pin). No Repair wiring harness. (Open circuit)
• Is resistance between terminals 2B and 2P
of front climate control unit connector (16-
pin) less than 7.8 kilohms?
4 • Is resistance between terminals 2B and 2G Yes Inspect the connection of the front climate control unit
of front climate control unit connector (16- connector.
pin) less than 6.24 kilohms? No Repair wiring harness. (Open circuit)
FRONT CLIMATE CONTROL UNIT CONNECTOR PASSENGER-SIDE FRONT AIR MIX
ACTUATOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–21
1890-1U-06H(07-02).fm 22 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 38
id070200803600

DTC 38 Passenger-side front air mix actuator (potentiometer) (past)

• Passenger-side front air mix actuator malfunction
POSSIBLE • Open circuit between passenger-side front air mix actuator and climate control unit
CAUSE • Short circuit between passenger-side front air mix actuator (terminal E) and front climate control unit
(terminal 2G: 16-pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect passenger-side front air mix actuator. Yes Go to the next step.
(See 07-40-6 FRONT AIR MIX ACTUATOR No Replace passenger-side front air mix actuator. (See 07-40-5
INSPECTION.) FRONT AIR MIX ACTUATOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and passenger-side front No Go to the next step.
air mix actuator connector.
• Is there open circuit between following
terminals of front climate control unit
connector (16-pin) and passenger-side front
air mix actuator connector?
— 2G—E
— 2B—A
— 2P—C
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2G of front climate control unit No This system is normal at present. (Erase the past failure
connector (16-pin) and terminal E of from memory.)
passenger-side front air mix actuator
connector?
FRONT CLIMATE CONTROL UNIT CONNECTOR
PASSENGER-SIDE FRONT AIR MIX
ACTUATOR CONNECTOR
2O 2M 2K 2I 2G 2E 2C 2A
G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–22
1890-1U-06H(07-02).fm 23 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 58
id070200803700

DTC 58 Driver-side front air mix actuator (motor lock) (past)

• Driver-side front air mix actuator malfunction
POSSIBLE
• Front A/C unit (air mix link and/or air mix crank) malfunction
CAUSE
• Open or short circuit between driver-side front air mix actuator and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect the driver-side front air mix Yes Connect driver-side front air mix actuator connector, then go
actuator connector. to Step 3.
• Connect battery positive voltage to terminal No Go to the next step.
F (or terminal G) and ground to terminal G
(or terminal F) of driver-side front air mix
actuator connector.
• Does driver-side front air mix actuator
operate?
2 • Remove driver-side front air mix actuator. Yes Replace driver-side front air mix actuator.
(See 07-40-5 FRONT AIR MIX ACTUATOR No Replace air mix link and/or air mix crank.
REMOVAL/INSTALLATION.)
• Operate air mix link by hand.
• Does air mix link operate smoothly?
3 • Disconnect climate control unit connect (24- Yes Inspect the connection of the front climate control unit
pin). connector. 07-02
• Connect battery positive voltage to terminal No Repair wiring harness.
1F (or terminal 1A) and ground to terminal
1A (or terminal 1F) of front climate control
unit connector (24-pin).
• Does driver-side front air mix actuator
operate?
FRONT CLIMATE CONTROL UNIT CONNECTOR
FRONT AIR MIX ACTUATOR CONNECTOR
(DRIVER-SIDE)

1W 1U 1S 1Q 1O 1M 1K 1I 1G 1E 1C 1A
G F E C A
1X 1V 1T 1R 1P 1N 1L 1J 1H 1F 1D 1B

End Of Sie

07-02–23
1890-1U-06H(07-02).fm 24 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 59
id070200803800

DTC 59 Front airflow mode actuator (motor lock) (past)

• Front airflow mode actuator malfunction
POSSIBLE
• Front A/C unit (airflow mode links and/or airflow mode cranks) malfunction
CAUSE
• Open or short circuit between front airflow mode actuator and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect front airflow mode actuator Yes Connect front airflow mode actuator connector, then go to
connector. Step 3.
• Connect battery positive voltage to terminal No Go to the next step.
F (or terminal G) and ground to terminal G
(or terminal F) of front airflow mode actuator
connector.
• Does front airflow mode actuator operate?
2 • Remove front airflow mode actuator. Yes Replace front airflow mode actuator.
(See 07-40-9 FRONT AIRFLOW MODE (See 07-40-9 FRONT AIRFLOW MODE ACTUATOR
ACTUATOR REMOVAL/INSTALLATION.) REMOVAL/INSTALLATION.)
• Operate airflow mode main link by hand. No Replace airflow mode links and/or airflow mode cranks.
• Does airflow mode main link operate
smoothly?
3 • Disconnect front climate control unit connect Yes Inspect the connection of the front climate control unit
(24-pin). connector.
• Connect battery positive voltage to terminal No Repair wiring harness.
1J (or terminal 1H) and ground to terminal
1H (or terminal 1J) of front climate control
unit connector (24-pin).
• Does front airflow mode actuator operate?
FRONT CLIMATE CONTROL UNIT CONNECTOR FRONT AIRFLOW MODE ACTUATOR CONNECTOR

1W 1U 1S 1Q 1O 1M 1K 1I 1G 1E 1C 1A
1X 1V 1T 1R 1P 1N 1L 1J 1H 1F 1D 1B G F E C A

End Of Sie

07-02–24
1890-1U-06H(07-02).fm 25 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 61
id070200803900

DTC 61 Passenger-side front air mix actuator (motor lock) (past)

• Passenger-side front air mix actuator malfunction
POSSIBLE
• Front A/C unit (air mix link and/or air mix crank) malfunction
CAUSE
• Open or short circuit between passenger-side front air mix actuator and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect passenger-side front air mix Yes Connect passenger-side front air mix actuator connector,
actuator connector. then go to Step 3.
• Connect battery positive voltage to terminal No Go to the next step.
F (or terminal G) and ground to terminal G
(or terminal F) of passenger-side front air mix
actuator connector.
• Does passenger-side front air mix actuator
operate?
2 • Remove passenger-side front air mix Yes Replace passenger-side front air mix actuator.
actuator. (See 07-40-5 FRONT AIR MIX No Replace air mix link and/or air mix crank.
ACTUATOR REMOVAL/INSTALLATION.)
• Operate air mix link by hand.
• Does air mix link operate smoothly?
3 • Disconnect front climate control unit connect Yes Inspect the connection of the front climate control unit
(24-pin). connector. 07-02
• Connect battery positive voltage to terminal No Repair wiring harness.
1C (or terminal 1E) and ground to terminal
1E (or terminal 1C) of front climate control
unit connector (24-pin).
• Does passenger-side front air mix actuator
operate?
FRONT AIR MIX ACTUATOR CONNECTOR
FRONT CLIMATE CONTROL UNIT CONNECTOR
(PASSENGER-SIDE)

1W 1U 1S 1Q 1O 1M 1K 1I 1G 1E 1C 1A
1X 1V 1T 1R 1P 1N 1L 1J 1H 1F 1D 1B G F E C A

End Of Sie

07-02–25
1890-1U-06H(07-02).fm 26 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 74
id070200806000

DTC 74 Rear climate control unit set airflow volume communication system (present)
POSSIBLE
• Open or short circuit between front climate control unit and rear climate control unit
CAUSE

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect front climate control unit Yes Repair wiring harness.
connector and rear climate control unit No Go to the next step.
connector.
• Is there open circuit between following
terminals of front climate control unit
connector and rear climate control unit
connector?
— 3E—A
— 3H—D
2 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 3I of front climate control unit No Inspect the connection of the front climate control unit and
connector and terminal E of rear climate rear climate control unit.
control unit connector?
FRONT CLIMATE CONTROL UNIT CONNECTOR REAR CLIMATE CONTROL UNIT CONNECTOR

3I 3G 3E 3C 3A A C E G
3J 3H 3F 3D 3B D F H

End Of Sie
DTC 75
id070200806100

DTC 74 Rear climate control unit set temperature communication system (present)
POSSIBLE
• Open or short circuit between front climate control unit and rear climate control unit
CAUSE

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect front climate control unit Yes Repair wiring harness.
connector and rear climate control unit No Go to the next step.
connector.
• Is there open circuit between following
terminals of front climate control unit
connector and rear climate control unit
connector?
— 3G—C
— 3H—D
2 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 3I of front climate control unit No Inspect the connection of the front climate control unit and
connector and terminal E of rear climate rear climate control unit.
control unit connector?
FRONT CLIMATE CONTROL UNIT CONNECTOR REAR CLIMATE CONTROL UNIT CONNECTOR

3I 3G 3E 3C 3A A C E G
3J 3H 3F 3D 3B D F H

End Of Sie

07-02–26
1890-1U-06H(07-02).fm 27 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 76
id070200804400

DTC 76 Rear air mix actuator (potentiometer) (present)

• Rear air mix actuator malfunction
POSSIBLE • Open circuit between rear air mix actuator and front climate control unit
CAUSE • Short circuit between rear air mix actuator (terminal E) and front climate control unit (terminal 2N: 16-
pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect rear air mix actuator. (See 07-40-8 Yes Go to the next step.
REAR AIR MIX ACTUATOR INSPECTION.) No Replace rear air mix actuator. (See 07-40-8 REAR AIR MIX
• Is it okay? ACTUATOR INSPECTION.)
2 • Disconnect driver side and passenger side Yes Go to the next step.
front air mix actuator connector. No Repair wiring harness. (Short circuit)
• Disconnect front airflow mode actuator
connector.
• Disconnect rear airflow mode actuator
connector.
• Disconnect ambient temperature sensor
connector.
• Disconnect cabin temperature sensor
connector.
• Disconnect front and rear evaporator 07-02
temperature sensor connector.
• Is resistance between terminals 2N and 2P
of front climate control unit connector (16-
pin) more than 840 ohms?
3 • Disconnect front climate control unit Yes Go to the next step.
connector (16-pin). No Repair wiring harness. (Open circuit)
• Is resistance between terminals 2B and 2P
of front climate control unit connector (16-
pin) less than 7.8 kilohms?
4 • Is resistance between terminals 2B and 2N Yes Inspect the connection of the front climate control unit
of front climate control unit connector (16- connector.
pin) less than 6.24 kilohms? No Repair wiring harness. (Open circuit)
FRONT CLIMATE CONTROL UNIT CONNECTOR REAR AIR MIX ACTUATOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–27
1890-1U-06H(07-02).fm 28 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 77
id070200804500

DTC 77 Rear air mix actuator (potentiometer) (past)

• Rear air mix actuator malfunction
POSSIBLE • Open circuit between rear air mix actuator and front climate control unit
CAUSE • Short circuit between rear air mix actuator (terminal E) and front climate control unit (terminal 2N: 16-
pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect rear air mix actuator. (See 07-40-8 Yes Go to the next step.
REAR AIR MIX ACTUATOR INSPECTION.) No Replace rear air mix actuator. (See 07-40-7 REAR AIR MIX
• Is it okay? ACTUATOR REMOVAL/INSTALLATION.)
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and rear air mix actuator No Go to the next step.
connector.
• Is there open circuit between following
terminals of front climate control unit
connector (16-pin) and rear air mix actuator
connector?
— 2N—E
— 2B—C
— 2P—A
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2N of front climate control unit No This system is normal at present. (Erase the past failure
connector (16-pin) and terminal E of rear air from memory.)
mix actuator connector?
FRONT CLIMATE CONTROL UNIT CONNECTOR
REAR AIR MIX ACTUATOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A
G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–28
1890-1U-06H(07-02).fm 29 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 78
id070200804600

DTC 78 Rear evaporator temperature sensor (present)

POSSIBLE • Rear evaporator temperature sensor malfunction
CAUSE • Open or short circuit between rear evaporator temperature sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Is resistance between terminals 2J and 2P of Yes Inspect the connection of the front climate control unit
front climate control unit connector (16-pin) connector.
as indicated below? No Go to the next step.
— 166 ohms—32 kilohms (-30—80 °C {-
22—176 °F})
— 2.107—2.575 kilohms (15 °C {59 °F})
2 • Inspect rear evaporator temperature sensor. Yes Repair wiring harness.
(See 07-40-21 REAR EVAPORATOR No Replace rear evaporator temperature sensor. (See 07-40-21
TEMPERATURE SENSOR INSPECTION.) REAR EVAPORATOR TEMPERATURE SENSOR
• Is it okay? REMOVAL/INSTALLATION.)
FRONT CLIMATE CONTROL UNIT CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A
2P 2N 2L 2J 2H 2F 2D 2B 07-02

End Of Sie

07-02–29
1890-1U-06H(07-02).fm 30 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 79
id070200804700

DTC 79 Rear evaporator temperature sensor (past)

POSSIBLE • Rear evaporator temperature sensor malfunction
CAUSE • Open or short circuit between rear evaporator temperature sensor and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect rear evaporator temperature sensor. Yes Go to the next step.
(See 07-40-21 REAR EVAPORATOR No Replace rear evaporator temperature sensor. (See 07-40-21
TEMPERATURE SENSOR INSPECTION.) REAR EVAPORATOR TEMPERATURE SENSOR
• Is it okay? REMOVAL/INSTALLATION.)
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and rear evaporator No Go to the next step.
temperature sensor connector.
• Is there open circuit between following
terminals of front climate control unit
connector (16-pin) and rear evaporator
temperature sensor connector?
— 2J—B
— 2P—A
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2J of front climate control unit No Connect front climate control unit connector, then go to the
connector (16-pin) and terminal B of rear next step.
evaporator temperature sensor connector?
4 • Turn ignition switch to ON position. Yes This system is normal at present. (Erase the past failure
• Measure voltage at terminal 2J of front from memory.)
climate control unit connector (16-pin). No Inspect the connection of the front climate control unit
• Is voltage approx. 5 V? connector.
FRONT CLIMATE CONTROL UNIT CONNECTOR REAR EVAPORATOR TEMPERATURE
SENSOR CONNECTOR
A
2O 2M 2K 2I 2G 2E 2C 2A B
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–30
1890-1U-06H(07-02).fm 31 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 85
id070200804800

DTC 85 Rear airflow mode actuator (potentiometer) (present)

• Rear airflow mode actuator malfunction
POSSIBLE • Open circuit between rear airflow mode actuator and front climate control unit
CAUSE • Short circuit between rear airflow mode actuator (terminal E) and front climate control unit (terminal 2D:
16-pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect rear airflow mode actuator. (See 07- Yes Go to the next step.
40-11 REAR AIRFLOW MODE ACTUATOR No Replace rear airflow mode actuator. (See 07-40-10 REAR
INSPECTION.) AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION.)
• Is it okay?
2 • Disconnect driver side and passenger side Yes Go to the next step.
front air mix actuator connector. No Repair wiring harness. (Short circuit)
• Disconnect front airflow mode actuator
connector.
• Disconnect rear air mix actuator connector.
• Disconnect ambient temperature sensor
connector.
• Disconnect cabin temperature sensor
connector.
• Disconnect front and rear evaporator
temperature sensor connector. 07-02
• Is resistance between terminals 2D and 2P
of front climate control unit connector (16-
pin) more than 840 ohms?
3 • Disconnect front climate control unit Yes Go to the next step.
connector (16-pin). No Repair wiring harness. (Open circuit)
• Is resistance between terminals 2B and 2P
of front climate control unit connector (16-
pin) less than 7.8 kilohms?
4 • Is resistance between terminals 2B and 2D Yes Inspect the connection of the front climate control unit
of front climate control unit connector (16- connector.
pin) less than 6.24 kilohms? No Repair wiring harness. (Open circuit)
RONT CLIMATE CONTROL UNIT CONNECTOR
REAR AIR FLOW MODE ACTUATOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–31
1890-1U-06H(07-02).fm 32 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 86
id070200804900

DTC 86 Rear airflow mode actuator (potentiometer) (past)

• Rear airflow mode actuator malfunction
POSSIBLE • Open circuit between rear airflow mode actuator and front climate control unit
CAUSE • Short circuit between rear airflow mode actuator (terminal E) and front climate control unit (terminal 2D:
16-pin)

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect rear airflow mode actuator. (See 07- Yes Go to the next step.
40-10 FRONT AIRFLOW MODE ACTUATOR No Replace rear airflow mode actuator. (See 07-40-21 REAR
INSPECTION.) EVAPORATOR TEMPERATURE SENSOR REMOVAL/
• Is it okay? INSTALLATION.)
2 • Disconnect front climate control unit Yes Repair wiring harness.
connector (16-pin) and rear airflow mode No Go to the next step.
actuator connector.
• Is there open circuit between following
terminals of front climate control unit
connector (16-pin) and rear airflow mode
actuator connector?
— 2B—A
— 2P—C
— 2D—E
3 • Is there short circuit to ground between Yes Repair wiring harness.
terminal 2D of front climate control unit No This system is normal at present. (Erase the past failure
connector (16-pin) and terminal E of rear from memory.)
airflow mode actuator connector?
ONT CLIMATE CONTROL UNIT CONNECTOR REAR AIRFLOW MODE ACTUATOR CONNECTOR

2O 2M 2K 2I 2G 2E 2C 2A G F E C A
2P 2N 2L 2J 2H 2F 2D 2B

End Of Sie

07-02–32
1890-1U-06H(07-02).fm 33 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 95
id070200805000

DTC 95 Rear air mix actuator (motor lock) (past)

• Rear air mix actuator malfunction
POSSIBLE
• Rear A/C unit (air mix link and/or air mix crank) malfunction
CAUSE
• Open or short circuit between rear air mix actuator and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect rear air mix actuator connector. Yes Connect rear air mix actuator connector, then go to Step 3.
• Connect battery positive voltage to terminal No Go to the next step.
F (or terminal G) and ground to terminal G
(or terminal F) of rear air mix actuator
connector.
• Does rear air mix actuator operate?
2 • Remove rear air mix actuator. (See 07-40-7 Yes Replace rear air mix actuator.
REAR AIR MIX ACTUATOR REMOVAL/ No Replace air mix link and/or air mix crank.
INSTALLATION.)
• Operate air mix link by hand.
• Does air mix link operate smoothly?
3 • Disconnect front climate control unit connect Yes Inspect the connection of the front climate control unit
(24-pin). connector.
• Connect battery positive voltage to terminal No Repair wiring harness.
1I (or terminal 1G) and ground to terminal 1G
(or terminal 1I) of front climate control unit
connector (24-pin).
• Does rear air mix actuator operate? 07-02
FRONT CLIMATE CONTROL UNIT CONNECTOR
REAR AIR MIX ACTUATOR CONNECTOR
1W 1U 1S 1Q 1O 1M 1K 1I 1G 1E 1C 1A
1X 1V 1T 1R 1P 1N 1L 1J 1H 1F 1D 1B G F E C A

End Of Sie

07-02–33
1890-1U-06H(07-02).fm 34 ページ ２００６年１２月１９日　火曜日　午後１２時５３分

ON-BOARD DIAGNOSTIC
DTC 96
id070200805100

DTC 96 Rear airflow mode actuator (motor lock) (past)

• Rear airflow mode actuator malfunction
POSSIBLE
• Rear A/C unit (airflow mode links and/or airflow mode cranks) malfunction
CAUSE
• Open or short circuit between rear airflow mode actuator and front climate control unit

Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect rear airflow mode actuator Yes Connect rear airflow mode actuator connector, then go to
connector. Step 3.
• Connect battery positive voltage to terminal No Go to the next step.
F (or terminal G) and ground to terminal G
(or terminal F) of rear airflow mode actuator
connector.
• Does rear airflow mode actuator operate?
2 • Remove rear airflow mode actuator. (See 07- Yes Replace rear airflow mode actuator.
40-10 REAR AIRFLOW MODE ACTUATOR No Replace airflow mode links and/or airflow mode cranks.
REMOVAL/INSTALLATION.)
• Operate airflow mode main link by hand.
• Does airflow mode main link operate
smoothly?
3 • Disconnect front climate control unit connect Yes Inspect the connection of the front climate control unit
(24-pin). connector.
• Connect battery positive voltage to terminal No Repair wiring harness.
1N (or terminal 1L) and ground to terminal 1L
(or terminal 1N) of front climate control unit
connector (24-pin).
• Does rear airflow mode actuator operate?

FRONT CLIMATE CONTROL UNIT CONNECTOR REAR AIRFLOW MODE ACTUATOR CONNECTOR

1W 1U 1S 1Q 1O 1M 1K 1I 1G 1E 1C 1A
G F E C A
1X 1V 1T 1R 1P 1N 1L 1J 1H 1F 1D 1B

End Of Sie

07-02–34
1890-1U-06H(07-03).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
07-03 SYMPTOM TROUBLESHOOTING
HVAC SYSTEM NO.5 WINDSHIELD FOGGED . . . . . . . . . 07-03–11
WIRING DIAGRAM . . . . . . . . . . . . . . . . 07-03–2 NO.6 INSUFFICIENT AIR (OR NO AIR)
FOREWORD . . . . . . . . . . . . . . . . . . . . . . 07-03–3 BLOWN REAR VENTS. . . . . . . . . . . . . . 07-03–13
TROUBLESHOOTING INDEX. . . . . . . . . 07-03–4 NO.7 AMOUNT OF AIR FROM REAR
NO.1 INSUFFICIENT AIR (OR NO AIR) VENTS DOES NOT CHANGE . . . . . . . . 07-03–14
BLOWN FROM FRONT VENTS . . . . . . 07-03–5 NO.8 AIR FROM FRONT/REAR VENTS
NO.2 AMOUNT OF AIR BLOWN NOT COLD ENOUGH. . . . . . . . . . . . . . . 07-03–16
FROM FRONT VENTS DOES NOT NO.9 NO COOL AIR FROM
CHANGE . . . . . . . . . . . . . . . . . . . . . . . . 07-03–5 FRONT/REAR VENTS . . . . . . . . . . . . . . 07-03–19
NO.3 AIR INTAKE MODE FROM NO.10 NOISE WHILE OPERATING A/C
FRONT VENT DOES NOT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 07-03–20
CHANGE . . . . . . . . . . . . . . . . . . . . . . . . 07-03–8 NO.11 DUAL A/C CONTROL DOES NOT
NO.4 NO TEMPERATURE CONTROL OPERATE . . . . . . . . . . . . . . . . . . . . . . . . 07-03–22
WITH FRONT CLIMATE
CONTROL UNIT . . . . . . . . . . . . . . . . . . 07-03–10

End of Toc
WM: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)

07-03

07-03–1
1890-1U-06H(07-03).fm 2 ページ ２００６年１２月２０日　水曜日　午前９時５２分

SYMPTOM TROUBLESHOOTING
HVAC SYSTEM WIRING DIAGRAM
id070300800100
Front
A/C RELAY

IG2
BCM
MAGNETIC
PCM CLUTCH
FRONT CLIMATE CONTROL UNIT
1W 1B
1S

CHECK 5V REFRIGERANT PRESSURE

1U
CONNECTOR SWITCH
5V 2B
2E
FRONT AIRFLOW
B MODE ACTUATOR
1J M
AMBIENT TEMPERATURE
1H
SENSOR
2I
CABIN TEMPERATURE
SENSOR 2F DRIVER-SIDE
2K FRONT AIR MIX ACTUATOR
1F M
FRONT EVAPORATOR
1A
TEMPERATURE SENSOR
2H

2P 2G PASSENGER-SIDE
SOLAR RADIATION FRONT AIR MIX ACTUATOR
A SENSOR 1C M
LH 1E
2M
RH CPU A
B
2O

1O
TNS RELAY 3D
1M AIR INTAKE ACTUATOR
1X
M IG2

INFORMATION
2C
DISPLAY FRONT BLOWER RELAY
M FRONT BLOWER MOTOR
INSTRUMENT
2A
CLUSTER 1P
REAR
FRONT POWER MOS FET
WINDOW 1Q 1R
DEFROSTER
RELAY
1D
SEAT WARMER
RELAY 1K

ac9uuw00002375

07-03–2
1890-1U-06H(07-03).fm 3 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
Rear

BCM
IG2

FRONT CLIMATE CONTROL UNIT

1W 1B

C
5V
5V
REAR EVAPORATOR
TEMPERATURE SENSOR
2B
2J
2D REAR AIRFLOW
2P
MODE ACTUATOR
1N M
1L

A 3E
2N REAR AIR MIX
C 3G ACTUATOR
1G M
J 3C CPU 1I
REAR CLIMATE G 3I
CONTROL UNIT
C 07-03
B 3F
REAR BLOWER RELAY
F 3H
M REAR BLOWER MOTOR
D 3J 1T

REAR POWER MOS FET

1V

INSTRUMENT
CLUSTER

ac9uuw00002459

End Of Sie
FOREWORD
id070300800200
• The areas for inspection (steps) are given according to various circuit malfunctions. Use the following chart to
verify the symptoms of the trouble in order to diagnose the appropriate area.
End Of Sie

07-03–3
1890-1U-06H(07-03).fm 4 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
TROUBLESHOOTING INDEX
id070300800300

No. TROUBLESHOOTING ITEM DESCRIPTION

1 Insufficient air (or no air) blown from front vents • Problem with each vent and/or duct
• Front airflow mode does not change when
switching front mode switch.
2 Amount of air blown from front vents does not change • Malfunction in front blower system
• Amount of air blown front vents does not change
when switching front climate control unit t airflow
control dial.
3 Air intake mode from front vent does not change • Malfunction in A/C unit and/or front climate control
unit air intake mode switching system
• Air intake mode does not change when switching
REC/FRESH mode.
4 No temperature control with front climate control unit • Malfunction in A/C unit and/or front climate control
unit air mix system
• Temperature does not change when switching front
climate control unit temperature setting dial.
5 Windshield fogged • Malfunction in A/C compressor control system and/
or air intake mode switching system
• A/C compressor does not operate while airflow
mode is DEFROSTER or HEAT/DEF modes.
• Air intake mode does not change to FRESH while
airflow mode is in DEFROSTER or HEAT/DEF
modes.
6 Insufficient air (or no air) from rear vent • Problem with each rear vent and/or duct
• Rear airflow mode does not change when front
and/or rear climate control unit mode switches.
7 Amount of air from rear vent does not change • Malfunction in rear blower motor system
• Amount of air blowing rear vents does not change
when switching front and/or rear climate control unit
airflow volume control dial.
8 Air from front/rear vents not cold enough • Malfunction in A/C basic system
• Magnetic clutch operates but A/C system
malfunctions.
9 No cool air from front/rear vents • Malfunction in A/C compressor control system
• Magnetic clutch does not operate when the A/C
system is turned ON.
10 Noise while operating A/C system • Problem with A/C basic system installation
• Noise from magnetic clutch, A/C compressor, hose
or refrigerant line.
11 Dual A/C control function does not operate • Malfunction in A/C unit and/or front climate control
unit dual A/C control system
• Driver or passenger-side temperature control dial
does not operate individually.

End Of Sie

07-03–4
1890-1U-06H(07-03).fm 5 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
NO.1 INSUFFICIENT AIR (OR NO AIR) BLOWN FROM FRONT VENTS
id070300801300

1 Insufficient air (or no air) blown from front vents

• Problem with each vent and/or duct
DESCRIPTION
• Front airflow mode does not change when switching front mode switch.
• Malfunction in front airflow mode actuator
POSSIBLE • Malfunction in front VENT mode system
CAUSE • Malfunction in front HEAT mode system
• Malfunction in front DEFROSTER mode system

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT FRONT AIRFLOW MODE Yes Go to the next step.
ACTUATOR No Repair or replace malfunctioning part in accordance with
• Is it okay? inspection result.
2 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 5.
IS IN FRONT VENT MODE OR OTHER MODES No Go to the next step.
• Does air blow out when in the front VENT
mode?
3 INSPECT FRONT VENT Yes Remove obstruction, then go to Step 9.
• Is the front vent clogged? No Go to the next step.
4 VERIFY THAT DUCT IN DASHBOARD IS Yes Inspect the duct for clogging, deformation and air leakage,
INSTALLED then go to Step 9. 07-03
• Is the duct in the dashboard properly No Install the duct securely in the proper position, then go to
installed? Step 9.
5 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN FRONT HEAT MODE OR FRONT No Inspect the vent for clogging, then go to Step 9.
DEFROSTER MODE
• Does air blow out when in the front HEAT
mode?
6 INSPECT FRONT DEFROSTER MODE Yes Operation is normal. Recheck malfunction symptoms.
• Does air blow out when in the front No Go to the next step.
DEFROSTER mode?
7 INSPECT FRONT VENT Yes Remove obstruction, then go to Step 9.
• Is the vent clogged? No Go to the next step.
8 VERIFY THAT DEFROSTER DUCT IS Yes Inspect the duct for clogging, deformation, and air leakage,
INSTALLED then go to the next step.
• Is the defroster duct properly installed? No Install the duct securely in proper position, then go to the
next step.
9 VERIFY REPAIR Yes Troubleshooting completed.
• Does air blow out? Explain repairs to customer.
No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.

End Of Sie
NO.2 AMOUNT OF AIR BLOWN FROM FRONT VENTS DOES NOT CHANGE
id070300801600

2 Amount of air blown from front vents does not change.

• Malfunction in front blower system
DESCRIPTION • Amount of air blown front vents does not change when switching front climate control unit airflow control
dial.
• Front A/C unit malfunction
POSSIBLE • Front blower motor malfunction
CAUSE • Malfunction in front power MOS FET system
• Front climate control unit malfunction

• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, inspect to make sure connectors, terminals and wiring harness are connected correctly and
undamaged.

07-03–5
1890-1U-06H(07-03).fm 6 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT HEATER BLOWER 40 A FUSE Yes Go to the next step.
• Is it normal? No Replace the fuse, then go to Step 15. If the fuse burns out
immediately, go to the next step.
2 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN A/C UNIT OR ELSEWHERE No Go to Step 4.
• Turn the ignition switch to the ON position.
• Turn the fan switch to ON position.
• Recirculate air inside the vehicle.
• Does the front blower motor operate normal
speed?
3 INSPECT FRONT A/C UNIT INTAKE VENT Yes Remove obstruction, then go to Step 15.
• Is front A/C unit intake vent clogged? No Inspect if there are any obstruction in the A/C unit passage,
then go to Step 15.
4* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 8.
IS IN FRONT BLOWER RELAY SYSTEM OR No Go to the next step.
FRONT POWER MOS FET SYSTEM
• Turn the ignition switch to ON position.
• Turn the fan switch to OFF position.
• Measure the voltage at the following front
blower motor terminal.
— Terminal B (blower motor operation
signal)
• Is voltage approx. 12 V?
5* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (OPEN CIRCUIT No Repair the wiring harness between the front blower relay
BETWEEN FUSE BLOCK AND FRONT and A/C 7.5A HEATER 50 A fuse, then go to Step 15.
BLOWER RELAY) OR ELSEWHERE
• Measure the voltage at the following front
blower relay terminals.
— Terminal B (IG2 signal)
— Terminal E (B+ signal)
• Is the voltage approx. 12 V?
6* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (OPEN CIRCUIT No Repair the wiring harness between the front blower relay
BETWEEN FRONT BLOWER RELAY AND and ground, then go to Step 15.
GROUND) OR ELSEWHERE
• Measure the voltage at the following front
blower relay terminal.
— Terminal D (GND signal)
• Is the voltage approx. 0 V?
7* INSPECT TO SEE WHETHER MALFUNCTION Yes Repair the wiring harness between the front blower relay
IS IN WIRING HARNESS (OPEN OR SHORT and blower motor, then go to Step 15.
CIRCUIT BETWEEN FRONT BLOWER RELAY No Replace the front blower relay, then go to Step 15.
AND FRONT BLOWER MOTOR) OR BLOWER
RELAY
• Measure the voltage at the following front
blower relay terminal.
— Terminal A (blower motor operation
signal)
• Is the voltage approx. 12 V?
8* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN BLOWER MOTOR OR ELSEWHERE No Inspect the front blower motor, then go to Step 15.
• Measure the voltage at the following blower
motor terminal.
— Terminal B (blower motor operation
signal)
• Is the voltage approx. 12 V?

07-03–6
1890-1U-06H(07-03).fm 7 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
9* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (OPEN OR SHORT No Repair the wiring harness between the front blower motor
CIRCUIT BETWEEN FRONT BLOWER and front power MOS FET, then go to Step 15.
MOTOR AND FRONT POWER MOS FET) OR
ELSEWHERE
• Measure the voltage at the following terminal
of front power MOS FET.
— Terminal A (blower motor operation
signal)
• Is voltage approx. 12 V?
10* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (OPEN OR SHORT No Repair the wiring harness between the front power MOS
CIRCUIT BETWEEN FRONT POWER MOS FET and ground, then go to Step 15.
FET AND GROUND) OR ELSEWHERE
• Measure the voltage at the following front
power MOS FET terminal.
— Terminal E (blower motor operation
signal)
• Is the voltage approx. 0 V?
11 INSPECT FRONT A/C UNIT Yes Go to the next step.
• Inspect the fan for following:. No Remove obstruction, repair or replace the fan and front A/C
— Is the fan free of interference with the A/C unit case, then go to Step 15.
unit case?
— Is the fan free of foreign material and 07-03
obstruction?
• Is the fan normal?
12* INSPECT TO SEE WHETHER MALFUNCTION Yes Replace the front power MOS FET, then go to Step 15.
IS IN FRONT POWER MOS FET OR No Go to the next step.
ELSEWHERE
• Disconnect front power MOS FET connector.
• Turn the fun switch to 1st position from off.
• Measure the voltage at the following front
power MOS FET terminal.
— Terminal B (blower motor control signal)
• Is voltage approx. 10 V?
13* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (OPEN CIRCUIT No Repair the wiring harness between the front power MOS
BETWEEN FRONT POWER MOS FET AND FET and climate control unit, then go to Step 15.
FRONT CLIMATE CONTROL UNIT) OR
ELSEWHERE
• Turn the ignition switch to the LOCK position.
• Disconnect front climate control unit
connector.
• Inspect for continuity at the following
terminals between the front power MOS FET
and front climate control unit.
— Terminal F—1R (blower motor control
signal)
— Terminal B—1P (blower motor feedback
signal)
• Is there continuity?
14* INSPECT TO SEE WHETHER MALFUNCTION Yes Repair the wiring harness between the front power MOS
IS IN CLIMATE CONTROL UNIT OR WIRING FET and ground, then go to the next step.
HARNESS (SHORT TO GROUND IN WIRING No Replace the front climate control unit, then go to the next
HARNESS BETWEEN FRONT POWER MOS step.
FET AND FRONT CLIMATE CONTROL UNIT)
• Inspect for continuity at the following terminal
between the power MOS FET and ground.
— Terminal D (blower motor control signal)—
ground
• Is there continuity?
15 VERIFY REPAIR Yes Troubleshooting completed.
• Is air discharged from vent? Explain repairs to customer.
No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.

End Of Sie

07-03–7
1890-1U-06H(07-03).fm 8 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
NO.3 AIR INTAKE MODE FROM FRONT VENT DOES NOT CHANGE
id070300801700

3 Air intake mode from front vent does not change.

• Malfunction in A/C unit and/or front climate control unit air intake mode switching system
DESCRIPTION
• Air intake mode does not change when switching REC/FRESH mode.
POSSIBLE • Air intake actuator malfunction
CAUSE • Air intake door malfunction

• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, inspect to make sure connectors, terminals and wiring harness are connected correctly and
undamaged.
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT AIR INTAKE ACTUATOR Yes Go to the next step.
• Is the air intake actuator normal? No Replace the air intake actuator, then go to Step 9.
2* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
(OPEN OR SHORT CIRCUIT) IS IN AIR No Go to Step 4.
INTAKE ACTUATOR, WIRING HARNESS
(BETWEEN CLIMATE CONTROL UNIT AND
AIR INTAKE ACTUATOR) OR ELSEWHERE
• Turn the ignition switch to the ON position.
• Measure the voltages at the following climate
control unit terminals.
— Terminal 1O (24-pin, RECIRCULATE
motor drive signal)
— Terminal 1M (24-pin, FRESH motor drive
signal)
(See 07-40-23 FRONT CLIMATE
CONTROL UNIT INSPECTION.)
• Are voltages normal?
3* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 7.
(OPEN OR SHORT CIRCUIT) IS IN AIR No Repair the wiring harness between the climate control unit
INTAKE ACTUATOR OR WIRING HARNESS and air intake actuator, then go to Step 9.
(BETWEEN CLIMATE CONTROL UNIT AND
AIR INTAKE ACTUATOR)
• Measure the voltages at the following air
intake actuator terminals.
— Terminal C (RECIRCULATE motor drive
signal)
— Terminal A (FRESH motor drive signal)
• Are voltages as shown below?
— Terminal C: approx. 0.5 V during FRESH
and approx. 10 V during RECIRCULATE
— Terminal A: approx. 10 V during FRESH
and approx. 0.5 V during RECIRCULATE
4 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect the air intake actuator, then go to Step 9.
IS IN AIR INTAKE ACTUATOR OR No Go to the next step.
ELSEWHERE
• Disconnect the air intake actuator connector.
• Measure the voltages at the following climate
control unit terminals.
— Terminal 1O (RECIRCULATE motor drive
signal)
— Terminal 1M (FRESH motor drive signal)
(See 07-40-23 FRONT CLIMATE
CONTROL UNIT INSPECTION.)
• Are voltages normal?

07-03–8
1890-1U-06H(07-03).fm 9 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
5 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (SHORT TO B+ No Repair the wiring harness between the climate control unit
BETWEEN CLIMATE CONTROL UNIT AND and air intake actuator, then go to Step 9.
AIR INTAKE ACTUATOR) OR ELSEWHERE
• Disconnect the climate control unit
connector.
• Measure the voltages at the following climate
control unit terminals.
— Terminal 1O (RECIRCULATE motor drive
signal)
— Terminal 1M (FRESH motor drive signal)
• Are voltages approx. 0 V?
6 INSPECT TO SEE WHETHER MALFUNCTION Yes Repair the wiring harness between the climate control unit
IS IN WIRING HARNESS (SHORT TO and air intake actuator, then go to Step 9.
GROUND BETWEEN CLIMATE CONTROL No Go to the next step.
UNIT AND AIR INTAKE ACTUATOR) OR
ELSEWHERE
• Turn the ignition switch to the LOCK position.
• Inspect for continuity at the following
terminals between the climate control unit
and ground.
— Terminal 1O (RECIRCULATE motor drive
signal)
— Terminal 1M (FRESH motor drive signal) 07-03
• Is there continuity?
7 INSPECT AIR INTAKE LINK Yes Go to the next step.
• Inspect the air intake links for followings: No Apply grease to the links. If any the links are damaged,
— Is there grease on link? replace the air intake actuator, then go to Step 9.
— Are the links securely and properly
installed?
— Are the links free of obstructions and
hindrances?
• Are the above items normal?
8 INSPECT TO SEE WHETHER MALFUNCTION Yes Replace the climate control unit, then go to the next step.
IS IN CLIMATE CONTROL UNIT OR AIR No Remove obstruction, or install the doors in the proper
INTAKE DOOR position. If any doors are cracked or damaged, replace
• Inspect the A/C unit air intake door. them, then go to the next step.
— Is the door free of obstructions, cracks,
and damage?
— Are the doors securely and properly
installed?
• Are the above items normal?
9 VERIFY REPAIR Yes Troubleshooting completed. Explain repairs to customer.
• Does the air intake mode change smoothly? No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.

End Of Sie

07-03–9
1890-1U-06H(07-03).fm 10 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
NO.4 NO TEMPERATURE CONTROL WITH FRONT CLIMATE CONTROL UNIT
id070300801800

4 No temperature control with front climate control unit

• Malfunction in A/C unit and/or front climate control unit air mix system
DESCRIPTION
• Temperature does not change when switching front climate control unit temperature setting dial.
• A/C unit air intake link, air intake crank, air intake rod, air intake wire, wire clamp malfunction
POSSIBLE • Climate control unit rack-and-pinion, air intake wire malfunction
CAUSE • A/C unit air intake door malfunction
• Heater piping malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT COOLANT TEMPERATURE Yes Go to the next step.
• Is the engine at operating temperature? No Warm up the engine, then go to Step 9.
2 INSPECT A/C UNIT AIR INTAKE SYSTEM Yes Go to the next step.
• Inspect the A/C unit air intake links, air intake No Apply grease or install the links, cranks, and rods securely in
cranks, air intake rods, air intake actuator, their proper positions, repair or replace the air intake
and wire clamp. actuator or wire clamp, then go to Step 9.
— Is there grease on links and cranks?
— Are links, cranks, and rods securely
installed in their proper positions?
— Is wire clamp free of deformation?
• Are the above items normal?
3 VERIFY THAT AIR INTAKE WIRE FROM A/C Yes Go to the next step.
UNIT IS POSITIONED SECURELY AND No Adjust the air intake wire or install securely in the correct
CORRECTLY (IF AVAILABLE) position, then go to Step 9.
• Is the air intake wire securely installed in the
correct position in relation to the A/C unit air
intake links?
4 INSPECT CLIMATE CONTROL UNIT Yes Go to the next step.
• Is the climate control unit normal? No Repair or replace the climate control unit, then go to Step 9.
5 INSPECT A/C UNIT Yes Remove obstruction, then go to Step 9.
• Is there any foreign material or obstruction in No Go to the next step.
the A/C unit air intake doors?
6 INSPECT A/C UNIT AIR INTAKE DOOR Yes Inspect the air intake door for cracks or damage, then go to
• Is the A/C unit air intake door securely and the next step.
properly installed? No Install the air intake door securely in the proper position,
then go to the next step.
7 INSPECT WIRING HANESS BETWEEN Yes Repair or replace malfunctioning part, then go to Step 9.
CLIMATE CONTROL UNIT AND FRONT AIR No Go to the next step.
MIX ACTUATOR
• Disconnect the front climate control unit
connector (24-pin, 16-pin).
• Inspect following wiring harness and
connectors for open, short or poor
connection of terminals.
— Between terminals 1A (climate control
unit) and G (driver-side front air mix
actuator)
— Between terminals 1F (climate control
unit) and F (driver-side front air mix
actuator)
— Between terminals 2F (climate control
unit) and E (driver-side front air mix
actuator)
— Between terminals 1C (climate control
unit) and G (passenger-side front air mix
actuator)
— Between terminals 1E (climate control
unit) and F (passenger-side front air mix
actuator)
— Between terminals 2G (climate control
unit) and E (passenger-side front air mix
actuator)
• Is there any open, short or poor connection
of terminals?

07-03–10
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SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
8 INSPECT HEATER LINE Yes Operation is normal. Recheck malfunction symptoms.
• Inspect the heater lines. No If heater piping connections are loose, tighten the
— Is the heater piping free of damage and connections to the specified torque.
cracks? Repair or replace the heater piping, then go to the next step.
— Are the heater piping connections free of
engine coolant leakage?
— Are the heater piping connections
securely tightened?
— Are the heater piping installation points on
A/C unit free of engine coolant leakage?
• Are the above items normal?
9 VERIFY REPAIR Yes Troubleshooting completed.
• Does the unit operate in every temperature Explain repairs to customer.
setting? No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.

End Of Sie
NO.5 WINDSHIELD FOGGED
id070300801900

5 Windshield fogged.
• Malfunction in A/C compressor control system and/or air intake mode switching system
• A/C compressor does not operate while airflow mode is DEFROSTER or HEAT/DEF modes.
DESCRIPTION
• Air intake mode does not change to FRESH while airflow mode is in DEFROSTER or HEAT/DEF 07-03
modes.
• Front climate control unit (B+ signal) system malfunction
POSSIBLE • Air intake actuator malfunction
CAUSE • Front climate control unit (RECIRCULATE, FRESH signal) system malfunction
• A/C unit air intake door malfunction

• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, inspect to make sure connectors, terminals and wiring harness are connected correctly and
undamaged.
Diagnostic procedure
STEP INSPECTION ACTION
1 COOL AIR BLOW OUT INSPECTION Yes Go to the next step.
• When both the A/C and fan switch in the front No Go to Step 1 of troubleshooting index No.8.
climate control unit are on, does cool air blow
out from the front vent?
2 INSPECT FRONT CLIMATE CONTROL UNIT Yes Go to the next step.
POWER SUPPLY FUSE FOR B+ SIGNAL No Inspect for a short to ground on blown fuse circuit.
• Is the front climate control unit power supply • Repair or replace if necessary. Install appropriate
fuse for B+ signal normal? amperage fuse.
3 INSPECT AIR INTAKE ACTUATOR Yes Go to the next step.
• Inspect the air intake actuator for followings. No Apply grease or install the link properly and securely,
— Is there grease on the link? remove obstruction, then go to Step 14.
— Is the link securely and properly
positioned?
— Is the link free of obstructions?
• Are the above items normal?
*4 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
FUSE BLOCK AND FRONT CLIMATE No Repair the wiring harness between the fuse block and front
CONTROL UNIT FOR CONTINUITY climate control unit, then go to Step 14.
• Disconnect the front climate control unit
connector (24-pin).
• Turn the ignition switch to the ON position.
• Measure the voltage at front climate control
unit terminal 1B (B+ signal).
• Is the voltage approx. 12 V?
*5 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
FRONT CLIMATE CONTROL UNIT AND No Repair the wiring harness between the front climate control
GROUND FOR VOLTAGE unit and ground, then go to Step 14.
• Measure the voltage at front climate control
unit terminal 1X (Ground).
• Is the voltage approx. 0V?

07-03–11
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SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
6 VERIFY WHETHER MALFUNCTION IS IN A/C Yes Go to the next step.
UNIT AIR INTAKE DOOR OR ELSEWHERE No Go to Step 12.
• Turn the ignition switch to the LOCK position.
• Connect the climate control unit connector
(24-pin).
• Remove the air intake actuator.
• Turn the ignition switch to the ON position.
• Set the fan switch to 4th position.
• Does the air intake mode (RECIRCULATE,
FRESH) change smoothly when the air
intake link is operated by hand?
7 INSPECT AIR INTAKE ACTUATOR Yes Go to the next step.
• Inspect the air intake actuator. No Replace the air intake actuator, go to Step 14.
(See 07-40-4 AIR INTAKE ACTUATOR
INSPECTION.)
• Is it normal?
8 INSPECT AIR INTAKE SELECTOR SWITCH Yes Go to the next step.
AND DEFROSTER SWITCH IN FRONT No Replace the front climate control unit, then go to Step 14.
CLIMATE CONTROL UNIT
• Measure the voltage at front climate control
unit connector (24-pin) terminals 1O and 1M.
• Is it normal?
*9 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
FRONT CLIMATE CONTROL UNIT AND AIR No Repair the wiring harness between the front climate control
INTAKE ACTUATOR FOR CONTINUITY unit and air intake actuator, then go to Step 14.
• Turn the ignition switch to the LOCK position.
• Is there continuity between the following front
climate control unit terminals and air intake
actuator terminals?
— Terminal C —Terminal 1O
(RECIRCULATE signal)
— Terminal A —Terminal 1M (FRESH signal)
*10 INSPECT WIRING HARNESS BETWEEN Yes Repair the wiring harness between the front climate control
FRONT CLIMATE CONTROL UNIT AND AIR unit and air intake actuator, then go to Step 14.
INTAKE ACTUATOR FOR SHORT TO No Go to the next step.
GROUND
• Is there continuity between the following front
climate control unit terminals and ground?
— Terminal 1O (RECIRCULATE signal)
— Terminal 1M (FRESH signal)
*11 INSPECT WIRING HARNESS BETWEEN Yes Repair the wiring harness between the front climate control
FRONT CLIMATE CONTROL UNIT AND AIR unit and air intake actuator, then go to Step 14.
INTAKE ACTUATOR FOR SHORT TO B+ No Replace the front climate control unit, then go to Step 14.
• Turn the ignition switch to the ON position
• Measure the voltage at the following front
climate control unit terminals.
— Terminal 1O (RECIRCULATE signal)
— Terminal 1M (FRESH signal)
• Is the voltage approx. 12 V?
12 INSPECT A/C UNIT AIR INTAKE DOOR Yes Remove obstruction, then go to Step 14.
• Is there any foreign material or obstruction in No Go to the next step.
the A/C unit air intake door?
13 VERIFY THAT A/C UNIT AIR INTAKE DOOR IS Yes Inspect the air intake door for cracks or damage, then go to
POSITIONED SECURELY AND PROPERLY the next step.
• Is the A/C unit air intake door securely and No Install the air intake door securely in the proper position,
properly positioned? then go to the next step.
14 VERFY REPAIR Yes Troubleshooting completed.
• Does the malfunction disappear? Explain repairs to customer.
No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.

End Of Sie

07-03–12
1890-1U-06H(07-03).fm 13 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
NO.6 INSUFFICIENT AIR (OR NO AIR) BLOWN REAR VENTS
id070300802000

6 Insufficient air (or no air) from rear vents

• Problem with each rear vent and/or duct
DESCRIPTION
• Rear airflow mode does not change when front and/or rear climate control unit mode switches.
• Rear vent mode malfunction
POSSIBLE • Rear heat mode malfunction
CAUSE • Rear airflow mode actuator malfunction
• Open, short circuit in wiring or poor connection between front and rear climate control unit

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the Step 6.
IS IN VENT MODE No Go to the next step.
• Does air blow out when in the rear vent
mode?
2 VERIFY THAT REAR HEATER CONTROL Yes Go to Step 4.
USING FRONT CLIMATE CONTROL UNIT No Go to the next step.
• Turn the rear heater to ON and OFF using
the front A/C control panel.
• Is it possible that the rear heater turns ON
and OFF using the front climate control unit?
3 INSPECT TO SEE WHETHER MALFUNCTION Yes Repair or replace malfunctioning part, then go to Step 10.
IS IN WIRING HARNESS (OPEN, SHORT OR No Go to the next step. 07-03
POOR CONNECTION OF TERMINALS
BETWEEN FRONT AND REAR CLIMATE
CONTROL UNIT) OR ELSEWHERE
• Inspect for open, short or poor connection of
terminals between front and rear climate
control unit.
— Terminal 3E (front)—terminal A (rear)
— Terminal 3G (front)—terminal C (rear)
— Terminal 3H (front)—terminal D (rear)
— Terminal 3I (front)—terminal E (rear)
— Terminal 3C (front)—terminal F (rear)
• Is there any open, short or poor connection
of terminals?
4 INSPECT VENT Yes Remove obstruction, then go to Step 10.
• Is the vent clogged? No Go to the next step.
5 VERIFY THAT REAR A/C DUCT IS Yes Inspect the duct for clogging, deformation and air leakage,
INSTALLED then go to Step 10.
• Is the rear A/C duct properly installed? No Install the duct securely in the proper position, then go to
Step 10.
6 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN REAR HEAT MODE No Inspect the rear vent for clogging, then go to Step 10.
• Does air blow out when in the rear heat
mode?
7 INSPECT REAR VENT Yes Remove obstruction, then go to Step 10.
• Is the rear vent clogged? No Go to the next step.
8 INSPECT REAR MODE ACTUATOR Yes Go to the next step.
• (See 07-40-11 REAR AIRFLOW MODE No Replace the rear airflow mode actuator, then go to Step 10.
ACTUATOR INSPECTION.)
• Is the rear airflow mode actuator normal?

07-03–13
1890-1U-06H(07-03).fm 14 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
9 INSPECT TO SEE WHETHER MALFUNCTION Yes Repair or replace malfunctioning part, then go to next step.
IS IN WIRING HARNESS (OPEN, SHORT OR No Replace the front climate control unit, go to the next step.
POOR CONNECTION OF TERMINALS
BETWEEN FRONT AND REAR AIRFLOW
MODE ACTUATOR) OR ELSEWHERE
• Inspect for open, short or poor connection of
terminals between front and rear airflow
mode actuator.
— Terminal 2P (front climate control unit)—
terminal C (rear airflow mode actuator)
— Terminal 2B (front climate control unit)—
terminal A (rear airflow mode actuator)
— Terminal 2D (front climate control unit)—
terminal E (rear airflow mode actuator)
— Terminal 1N (front climate control unit)—
terminal F (rear airflow mode actuator)
— Terminal 1L (front climate control unit)—
terminal G (rear airflow mode actuator)
• Is there any open, short or poor connection
of terminals?
10 VERIFY REPAIR Yes Troubleshooting completed.
• Does air blow from the rear A/C vent mode? Explain repairs to customer.
No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.

End Of Sie
NO.7 AMOUNT OF AIR FROM REAR VENTS DOES NOT CHANGE
id070300901500

7 Amount of air from rear vents does not change

• Malfunction in rear blower motor system
DESCRIPTION • Amount of air blowing rear vents does not change when switching front and/or rear climate control unit
airflow volume control dial.
• Rear A/C unit malfunction
POSSIBLE • Rear blower motor malfunction
CAUSE • Rear power MOS FET malfunction
• Rear climate control unit malfunction

• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, inspect to make sure connectors, terminals and wiring harness are connected correctly and
undamaged.
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN REAR A/C UNIT OR ELSEWHERE No Go to Step 3.
• Turn the ignition switch to the ON position.
• Turn the rear fan switch the ON position.
• Does the blower motor rotate smoothly?
2 INSPECT REAR A/C UNIT INTAKE VENT Yes Remove obstruction, then go to Step 13.
• Is the rear A/C unit intake vent clogged? No Inspect if there are any obstructions in the rear A/C unit
passage, then go to Step 13.
3* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the Step 7.
IS IN REAR BLOWER RELAY SYSTEM OR No Go to the next step.
REAR POWER MOS FET
• Turn the ignition switch to ON position.
• Turn the rear fan switch to OFF position.
• Measure the voltage at the following rear
blower motor terminal.
— Terminal B (rear blower motor operation
signal)
• Is the voltage normal (B+)?

07-03–14
1890-1U-06H(07-03).fm 15 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
4* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (OPEN OR SHORT No If the terminal A voltage is not normal, repair or replace
CIRCUIT BETWEEN FUSE BLOCK AND wiring harness between A/C 7.5 A fuse and rear blower
REAR BLOWER RELAY) OR ELSEWHERE relay.
• Measure the voltage at the following rear If the terminal D voltage is not normal, repair or replace
relay terminals. wiring harness between R.HEATER 40 A fuse and rear
— Terminal A (IG2 signal) blower relay.
— Terminal D (B+ signal) Then go to Step 13.
• Is the voltage approx. 12 V?
5* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (OPEN CIRCIT No Repair or replace for open circuit between rear blower relay
BETWEEN REAR BLOWER RELAY AND and GND, then go to Step 13.
GROUND) OR ELSEWHERE
• Measure the voltage at the following rear
blower relay terminal.
— Terminal E (GND signal)
• Is the voltage approx. 0 V?
6* INSPECT TO SEE WHETHER MALFUNCTION Yes Repair or replace for open or short circuit between rear
IS IN WIRING HARNESS (OPEN OR SHORT blower relay and rear blower motor, then go to Step 13.
CIRCUIT BETWEEN REAR BLOWER RELAY No Replace the rear blower relay, then go to Step 13.
AND REAR BLOWER MOTOR) OR
ELSEWHERE
• Measure the voltage at the following rear
blower relay terminal. 07-03
— Terminal B (blower motor operation
signal)
• Is the voltage approx. 12 V?
7* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN REAR BLOWER MOTOR OR No Replace the rear blower motor, then go to Step 13.
ELSEWHERE
• Measure the voltage at the following rear
blower motor terminal.
— Terminal A (blower motor operation
signal)
• Is the voltage approx. 12 V?
8* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (OPEN OR SHORT No Repair or replace for open or short circuit between rear
CIRCUIT BETWEEN REAR BLOWER MOTOR blower motor and rear power MOS FET, then go to Step 13.
AND REAR POWER MOS FET) OR
ELSEWHERE
• Measure the voltage at the following rear
power MOS FET terminal.
— Terminal B (blower motor operation
signal)
• Is the voltage approx. 12 V?
9* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (OPEN CIRCUIT No Repair or replace for open circuit between rear power MOS
BETWEEN REAR POWER MOS FET AND FET and GND, then go to Step 13.
GROUND) OR ELSEWHERE
• Is there continuity at the following terminals?
— Terminal (wiring harness-side connector)
A—GND
10 INSPECT REAR A/C UNIT Yes Go to the next step.
• Inspect the fan in rear A/C unit. No Remove obstruction, repair or replace the fan blower unit
— Is the fan free of interference with the rear case, then go to Step 13.
A/C unit case?
— Is the fan free of foreign material and
obstructions?
• Is the fan normal?

07-03–15
1890-1U-06H(07-03).fm 16 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
11* INSPECT TO SEE WHETHER MALFUNCTION Yes Replace the rear power MOS FET, then go to the next step.
IS IN WIRING HARNESS (OPEN CIRCUIT No Repair or replace for open circuit between the rear power
BETWEEN REAR POWER MOS FET AND MOS FET and the front climate control unit, then go to Step
CLIMATE CONTROL UNIT) OR ELSEWHERE 13.
• Turn the ignition switch to LOCK position.
• Disconnect the front climate control unit
connector (24-pin).
• Is there continuity following terminals at
harness-side connector.
— Terminal D (rear power MOS FET) and
terminal 1T (front climate control unit)
— Terminal C (rear power MOS FET) and
terminal 1V (front climate control unit)
12 INSPECT TO SEE WHETHER MALFUNCTION Yes Troubleshooting completed.
IS IN REAR POWER MOS FET OR Explain repairs to customer.
ELSEWHERE No Replace the front climate control unit, then go to the next
• Is the air discharged from rear vent after step.
replace the rear power MOS FET?
13 VERIFY REPAIR Yes Troubleshooting completed.
• Is the air discharged from rear vent? Explain repairs to customer.
No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.

End Of Sie
NO.8 AIR FROM FRONT/REAR VENTS NOT COLD ENOUGH
id070300901200

8 Air from front/rear vents not cold enough.

• Malfunction in A/C basic system
DESCRIPTION
• Magnetic clutch operates but A/C system malfunctions.
• Drive belt malfunction
• A/C unit or condenser malfunction
POSSIBLE • Receiver/drier or expansion valve malfunction (valve closes too much)
CAUSE • Malfunction in refrigerant lines
• A/C compressor system malfunction, insufficient compressor oil
• Over filling of compressor oil, malfunction in expansion valve or A/C unit air mix link system

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVE BELT Yes Go to the next step.
• Inspect the drive belt. No Adjust or replace the drive belt, then go to Step 20.
(See 01-10-4 DRIVE BELT INSPECTION (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION
[MZI-3.5].) [MZI-3.5].)
• Is it normal?
2 INSPECT REFRIGERANT SYSTEM Yes Operation is normal. (Recheck malfunction symptoms.)
PERFORMANCE No Go to the next step.
• Perform refrigerant system performance test.
(See 07-10-7 REFRIGERANT SYSTEM
PERFORMANCE TEST.)
• Is the operation normal?
3 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN A/C UNIT INTAKE AND CONDENSER No Go to Step 6.
OR ELSEWHERE
• Are the refrigerant high-pressure and low-
pressure values both high?
4 INSPECT A/C UNIT INTAKE Yes Remove obstruction, then go to Step 20. (If air does not
• Is the A/C unit intake clogged? reach the evaporator in the A/C unit, heat exchange does
not occur and refrigerant pressure becomes high.
Therefore, removal of obstruction is necessary.)
No Go to the next step.
5 INSPECT CONDENSER Yes Adjust refrigerant to the specified amount, then go to Step
• Inspect the condenser. 20. (Excessive amount of refrigerant.)
(See 07-11-15 CONDENSER No Replace the condenser, or repair and clean the condenser
INSPECTION.) fins, then go to Step 20.
• Is it normal?

07-03–16
1890-1U-06H(07-03).fm 17 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
6 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN EXPANSION VALVE, RECEIVER/DRIER No Go to Step 14.
AND REFRIGERANT LINES OR ELSEWHERE
• Are the refrigerant high-pressure and low-
pressure values low?
7 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN EXPANSION VALVE AND RECEIVER/ No Go to Step 10.
DRIER OR ELSEWHERE
• Immediately after the A/C compressor
operates, does the refrigerant high-pressure
value momentarily rise to correct value, then
fall and stay below it? (Is there negative
pressure on low-pressure side?)
8 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN EXPANSION VALVE OR RECEIVER/ No Replace the condenser and vacuum the refrigerant line
DRIER more than 30 min by the vacuum pump, add refrigerant to
• Turn the A/C switch off and let the air the specified level, then go to Step 20. (Since water has
conditioner stop for 10 min. intermixed in the receiver/drier and it is saturated,
• Start the engine. replacement is necessary.)
• Turn the both A/C switch and fan switch on.
• Does the malfunction occur after the A/C
compressor turns on?
9 VERIFY THAT EXPANSION VALVE HEAT- Yes Replace the expansion valve, then go to Step 20. (Since the
SENSING TUBE WITHIN A/C UNIT IS valve closes too much, replacement is necessary.) 07-03
POSITIONED SECURELY AND CORRECTLY No Install the heat-sensing tube securely in the proper position,
• Is the expansion valve heat-sensing tube in then go to Step 20.
the A/C unit securely installed in the proper
position?
10 INSPECT REFRIGERANT LINE Yes Go to the next step.
• Inspect the refrigerant lines. No If the piping or A/C component (s) are damaged or cracked,
— Is the piping free of damage and cracks? replace them.
— Are the piping connections free of oil Then go to Step 20.
grime? (Visual inspection) If there is no damage, go to Step 13.
— Are the piping connections free of gas
leakage?
— Are the piping installation points on the
condenser free of gas leakage?
— Are the piping installation points on the
receiver/drier free of gas leakage?
— Are the piping installation points on the A/
C compressor free of gas leakage?
— Are the piping installation points on the A/
C unit free of gas leakage?
— Perform gas leakage inspection using a
gas leak tester.
• Are the above items normal?
11 INSPECT EVAPORATOR PIPING Yes If the vane makes a noise, add 10 ml {10 cc, 0.34 fl oz} of
CONNECTION IN A/C UNIT FOR GAS compressor oil to the A/C compressor. Verify that the noise
LEAKAGE is no longer heard.
• Are piping the connections for the evaporator Adjust refrigerant to the specified amount, then go to Step
in the A/C unit free of gas leakage? 20.
No If the piping is damaged or cracked, replace it.
Then go to Step 20.
If there is no damage, go to the next step.
12 INSPECT EVAPORATOR PIPING Yes Tighten the connections to the specified torque, adjust both
CONNECTION IN A/C UNIT FOR LOOSE compressor oil and refrigerant to the specified amount, then
• Are the piping connections for the evaporator go to Step 20.
in the A/C unit loose? No If the vane makes a noise, add 10 ml {10 cc, 0.34 fl oz} of
compressor oil to the A/C compressor. Verify that the noise
is no longer heard.
Replace the O-ring on piping, adjust refrigerant to the
specified amount, then go to Step 20.

07-03–17
1890-1U-06H(07-03).fm 18 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
13 INSPECT PIPING CONNECTION FOR LOOSE Yes Tighten the connections to the specified torque, adjust both
• Are the piping connections loose? compressor oil and refrigerant to the specified amount, then
go to Step 20.
No If the vane makes a noise, add 10 ml {10 cc, 0.34 fl oz} of
compressor oil to the A/C compressor. Verify that the noise
is no longer heard.
Replace O-ring on piping, adjust refrigerant to specified
amount, then go to Step 20.
14 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step. (Pressure hardly increases.)
IS IN EXPANSION VALVE, AIR MIX No Go to Step 17.
ACTUATOR AND COMPRESSOR OIL OR
ELSEWHERE
• Does the refrigerant high-pressure value
hardly increase?
15 INSPECT TO SEE WHETHER MALFUNCTION Yes Return to Step 3.
IS IN COMPRESSOR OIL AMOUNT AND A/C No Go to the next step.
COMPRESSOR OR ELSEWHERE
• When the engine is racing, does the high-
pressure value increase?
16 INSPECT TO SEE WHETHER MALFUNCTION Yes Troubleshooting completed. (Explain to customer that cause
IS IN COMPRESSOR OIL AMOUNT OR A/C was insufficient compressor oil.)
COMPRESSOR No Replace the A/C compressor, then go to Step 20. (Cause is
• After compressor oil is replenished each 10 defective A/C compressor.)
ml {10 cc, 0.34 fl oz}, does high-pressure
value increase?
17 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 19.
IS IN EXPANSION VALVE OR ELSEWHERE No Go to the next step.
• Is only refrigerant low-pressure value high?
18 VERIFY THAT AIR MIX IS INSTALLED Yes Set the fan switch to 4th position.
SECURELY AND PROPERLY Turn the A/C switch on.
• Are the front (driver and passenger side ) Set FRESH mode.
and rear A/C unit air mix links, air mix cranks, Set temperature control to MAX COLD.
and air mix rods securely and properly Set VENT mode.
installed? (1)Start and run the engine at 1,500 rpm for 10 min.
(2)Run the engine at idle for 1 min.
(3)Within 12 s, idle → 4,000 rpm → idle. Perform cycle 5
times.
(4) Run the engine at idle for 30 s.
(5)Drain the compressor oil completely from the A/C
compressor and verify the amount.
• If there is approx. 90 ml {90 cc, 3.0 fl oz} of
compressor oil, go to Step 20.
• If there is more than 90 ml {90 cc, 3.0 fl oz} of
compressor oil, remove surplus oil and fill the A/C
compressor with 90 ml {90 cc, 3.0 fl oz} of
compressor oil. Repeat Steps (1) to (5).
(Cause is excessive amount of compressor oil.)
No Repair or install the links, cranks and rods securely in the
proper position, then go to Step 20.
19 VERIFY THAT EXPANSION VALVE HEAT- Yes Replace the expansion valve, then go to the next step.
SENSING TUBE WITHIN A/C UNIT IS (Since the valve opens too much, replacement is
POSITIONED SECURELY AND CORRECTLY necessary.)
• Is the expansion valve heat-sensing tube in No Install the heat-sensing tube securely in the proper position,
the A/C unit securely installed in the proper then go to the next step.
position?
20 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
OCCURS AFTER REPAIR Explain repairs to customer.
• Does cool air blow out? (Are results of No Recheck malfunction symptoms, then repeat from Step 1 if
refrigerant system performance test the malfunction recurs.
normal?)

End Of Sie

07-03–18
1890-1U-06H(07-03).fm 19 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
NO.9 NO COOL AIR FROM FRONT/REAR VENTS
id070300901400

9 No cool air from front/rear vents

• Malfunction in A/C compressor control system
DESCRIPTION
• Magnetic clutch does not operate when the A/C system is turned ON.
• Malfunction in PCM A/C cut control system
• Malfunction in climate control unit
• Malfunction in refrigerant pressure switch
• Malfunction in PCM (A/C signal)
POSSIBLE
• Malfunction in PCM (IG1 signal)
CAUSE
• Malfunction in A/C compressor
• Malfunction in A/C relay
• Malfunction in evaporator temperature sensor
• Malfunction in BCM unit

• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are
connected correctly and undamaged.
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT AIR FLOW FROM VENTS Yes Go to the next step.
• Does air blow out? No Go to Step 1 of troubleshooting indexes No.1 and 2.
2 INSPECT A/C COMPRESSOR OPERATION Yes Go to Step 1 of troubleshooting index No.7. 07-03
• Start engine. No Go to the next step.
• Turn A/C switch and fan switch on.
• Does A/C compressor operate?
3 INSPECT FOR DTC IN PCM Yes Go to appropriate inspection procedure.
• Inspect for DTCs related to the PCM on- No Go to the next step.
board diagnostic system.
• Are any DTCs displayed?
4 INSPECT TO SEE WHETHER MALFUNCTION Yes Replace climate control unit, then go to Step 16.
IS IN CLIMATE CONTROL UNIT OR No Release short, then go to the next step.
ELSEWHERE
• Does cool air blow out when terminal 1S of
climate control unit connector (24-pin, A/C
signal) is grounded?
5* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 7.
IS IN A/C SIGNAL CIRCUIT (BETWEEN No Go to the next step.
REFRIGERANT PRESSURE SWITCH AND
PCM) OR ELSEWHERE
• Test voltage at following terminal of
refrigerant pressure switch.
— Terminal B (A/C signal)
• Is voltage approx. 12 V?
6* INSPECT TO SEE WHETHER MALFUNCTION Yes Repair wiring harness between PCM and refrigerant
IS IN WIRING HARNESS (BETWEEN pressure switch, then go to Step 16.
REFRIGERANT PRESSURE SWITCH AND No Inspect PCM, then go to Step 16.
PCM) OR PCM
• Test voltage at A/C signal terminal of PCM.
• Is voltage approx. 12 V?
7 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN REFRIGERANT PRESSURE SWITCH, No Go to Step 9.
REFRIGERANT AMOUNT, OR ELSEWHERE
• Does cool air blow out when terminals B and
C of refrigerant pressure switch connector
are shorted?
8 INSPECT TO SEE WHETHER MALFUNCTION Yes If refrigerant amount is empty, replace condenser, vacuum
IS IN REFRIGERANT PRESSURE SWITCH OR refrigerant line more than 30 min by vacuum pump, and
REFRIGERANT AMOUNT add refrigerant to specified level, then go to Step 16.
• Inspect refrigerant pressure switch. No Replace refrigerant pressure switch, then go to Step 16.
• Is it okay?

07-03–19
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SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
9 INSPECT TO SEE WHETHER MALFUNCTION Yes Release short, then go to the next step.
(SHORT CIRCUIT) IS IN A/C CONTROL No Go to Step 11.
SIGNAL CIRCUIT (BETWEEN A/C RELAY
AND PCM) OR ELSEWHERE
• Does cool air blow out when terminal A of A/
C relay connector (A/C control signal) is
grounded?
10* INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect PCM, then go to Step 16.
(OPEN OR SHORT CIRCUIT) IS IN PCM OR No Repair wiring harness between A/C relay and PCM, then go
WIRING HARNESS (BETWEEN A/C RELAY to Step 16.
AND PCM)
• Test voltage at the A/C relay control signal
terminal of PCM.
• Is voltage approx. 12 V?
11* INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect magnetic clutch, then go to Step 16.
IS IN MAGNETIC CLUTCH OR ELSEWHERE No Go to the next step.
• Test voltage at the following terminal of
magnetic clutch thermal protector.
— Terminal B (magnetic clutch operation
signal)
• Is voltage approx. 12 V?
12 INSPECT FUSE Yes Go to the next step.
• Are A/C relay power supply fuses okay? No Replace fuse, then go to Step 16. If fuse burns out
immediately, go to the next step.
13 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
FUSE BLOCK AND A/C RELAY FOR LACK OF No Repair wiring harness between fuse block and A/C relay,
CONTINUITY then go to Step 16.
• Test voltages at following terminals of A/C
relay.
— Terminal E (A/C relay control signal)
— Terminal C (A/C control signal)
• Are voltages approx. 12 V?
14 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect wiring harness between A/C relay and magnetic
IS IN A/C RELAY OR WIRING HARNESS clutch.
(BETWEEN A/C RELAY AND MAGNETIC • If above wiring harness is OK, go to the next step.
CLUTCH) AND EVAPORATOR • If above wiring harness malfunctions, repair wiring
TEMPERATURE SENSOR harness, then go to Step 16.
• Test voltage at the following terminal of A/C No Replace A/C relay, then go to Step 16.
relay.
— Terminal D (magnetic clutch operation
signal)
• Is voltage approx. 12 V?
15 INSPECT EVAPORATOR TEMPERATURE Yes Go to the next step.
SENSOR No Replace evaporator temperature sensor, then go to the next
• Inspect evaporator temperature sensor. step.
• Is it okay?
16 VERIFY REPAIR Yes Troubleshooting completed. Explain repairs to customer.
• Does cool air blow out from front/rear vents? No Recheck malfunction symptoms, then repeat from Step 1 if
(Are the results of refrigerant system malfunction recurs.
performance test okay?)

End Of Sie
NO.10 NOISE WHILE OPERATING A/C SYSTEM.
id070300801400

10 Noise while operating A/C system.

• Problem with A/C basic system installation
DESCRIPTION
• Noise from magnetic clutch, A/C compressor, hose or refrigerant line.
• Magnetic clutch operation noise
POSSIBLE • A/C compressor vane noise
CAUSE • A/C compressor slippage noise
• Hose or refrigerant line interference noise

07-03–20
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SYMPTOM TROUBLESHOOTING
Diagnostic procedure
STEP INSPECTION ACTION
1 CHECK A/C COMPRESSOR VANE NOISE Yes Go to Step 5.
• Is there a jingling, popping, beeping, or No Go to the next step.
buzzing sound (A/C compressor vane
noise)?
2 INSPECT A/C COMPRESSOR SLIPPAGE Yes Go to Step 14.
NOISE No Go to the next step.
• Is there a squeaking or whirling sound (A/C
compressor slippage noise)?
3 INSPECT A/C COMPRESSOR Yes Go to Step 18.
INTERFERENCE NOISE No Go to the next step.
• Is there a rattling or vibrating sound
(interference noise)?
4 INSPECT MAGNETIC CLUTCH OPERATION Yes Adjust clearance between pressure plate of magnetic clutch
NOISE and A/C compressor pulley, then go to Step 19.
• Is there a clicking sound (magnetic clutch (See 07-40-16 MAGNETIC CLUTCH ADJUSTMENT.)
operation noise)? No Condition is normal. (Recheck malfunction symptoms.)
5 INSPECT A/C COMPRESSOR NOISE TIME Yes Go to the next step.
• Is noise heard continuously for more than 3 No Condition is normal. (Noise occurs for 2—3 s immediately
s after A/C compressor comes on? after A/C compressor turns on.)
6 INSPECT IDLE SPEED Yes Go to the next step.
• Inspect idle speed. No Follow the repair instruction described in section 01, then go
(See 01-10-57 ENGINE TUNE-UP [MZI- 07-03
to Step 19.
3.5].)
• Is it okay?
7 INSPECT REFRIGERANT AMOUNT Yes Go to Step 10.
• Inspect refrigerant amount. No Go to the next step.
• Is it okay?
8 INSPECT REFRIGERANT LINES Yes Go to the next step.
• Inspect refrigerant lines. No If piping or A/C component(s) is damaged or cracked,
— Is piping free of damage and cracks? replace then go to Step 19.
— Are piping connections free of oil grime? If there is gas leakage, repair or replace connection and
(Visual inspection) replace condenser*, then go to Step 19.
— Are piping connections free of gas
leakage?
— Are piping installation points on
condenser free of gas leakage?
— Are piping installation points on receiver/
drier free of gas leakage?
— Are piping installation points on A/C
compressor free of gas leakage?
— Are piping installation points on A/C unit
free of gas leakage
— Perform gas leak inspection using gas
leak tester.
• Are above items okay?
9 INSPECT EVAPORATOR PIPING Yes Adjust refrigerant amount to specified level, then go to Step
CONNECTIONS IN A/C UNIT FOR GAS 19.
LEAKAGE No If piping is damaged or cracked, replace then go to Step 19.
• Are piping connections for evaporator in A/C If there is gas leakage, repair or replace connection and
unit free of gas leakage? replace condenser*, then go to Step 19.
10 CHECK TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN COMPRESSOR OIL OR ELSEWHERE No Troubleshooting completed.
• Add 20 ml {20 cc, 0.8 fl oz} of compressor Explain repair to customer.
oil.
• Is noise heard when racing engine?
11 CHECK TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN A/C COMPRESSOR OR ELSEWHERE No Replace A/C compressor, then go to Step 19.
• Drain compressor oil.
• Is it contaminated with metal particles?
12 CHECK TO SEE WHETHER MALFUNCTION Yes Replace entire A/C system (excluding heater), then go to
IS SOMEWHERE IN A/C SYSTEM OR Step 19.
ELSEWHERE No Go to the next step.
• Is compressor oil whitish and mixed with
water?

07-03–21
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SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
13 INSPECT A/C COMPRESSOR OIL Yes Replace A/C compressor and condenser, then go to Step
• Is compressor oil darker than normal and 19. (Since A/C compressor may be worn and receiver/drier
contaminated with aluminum chips? may be clogged, replacement of receiver/drier is necessary.)
No Condition is normal. Recheck malfunction symptoms.
14 CHECK TO SEE WHETHER MALFUNCTION Yes Replace A/C compressor, then go to Step 19. (A/C
IS IN A/C COMPRESSOR OR ELSEWHERE compressor discharge valve left open)
• Is noise heard immediately after A/C No Go to the next step.
compressor is stopped?
15 INSPECT DRIVE BELT Yes Go to the next step.
• Inspect drive belt. No Adjust or replace drive belt, then go to Step 19.
(See 01-10-4 DRIVE BELT INSPECTION
[MZI-3.5].)
• Is it okay?
16 INSPECT DRIVE BELT CONDITION Yes Remove obstruction, remove oil, or replace drive belt, then
• Is drive belt worn? go to Step 19.
• Does it have foreign material imbedded in it, No Go to the next step.
or have oil on it?
17 INSPECT MAGNETIC CLUTCH Yes Replace A/C compressor (excluding pressure plate, A/C
• Inspect magnetic clutch. compressor pulley, and stator), then go to Step 19.
(See 07-40-17 MAGNETIC CLUTCH No Replace magnetic clutch, then go to Step 19.
INSPECTION.)
• Is it okay?
18 CHECK TO SEE WHETHER MALFUNCTION Yes Visually inspect A/C compressor, replace appropriate parts
IS IN A/C COMPRESSOR OR REFRIGERANT if necessary, then go to the next step.
LINES No If noise is due to refrigerant lines, repair detached or
• Is noise emitted from A/C compressor? missing clips, tighten loose bolts, then go to the next step.
19 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
OCCURS AFTER REPAIR Explain repairs to customer.
• Has A/C compressor noise stopped? No Recheck malfunction symptoms, then repeat from Step 1 if
malfunction recurs.

* : If there is gas leakage, air enters into the A/C system. The desiccant within the receiver/drier absorbs the
moisture from the air and becomes saturated. If the A/C system is used in this condition, the inside of the A/C
compressor will begin to rust due to this moisture, which may cause lock up or noise to occur. Therefore,
replacement of the receiver/drier is necessary.

End Of Sie
NO.11 DUAL A/C CONTROL DOES NOT OPERATE
id070300801500

11 Dual A/C control function does not operate

DESCRIPTION • Driver or passenger-side temperature control does not operate individually
• Driver-side air mix door malfunction (stuck)
• Passenger-side air mix door malfunction (stuck)
• driver-side front air mix actuator malfunction
• Passenger-side front air mix actuator malfunction
• Driver-side front air mix actuator position sensor malfunction
• Passenger-side front air mix actuator position sensor malfunction
• Open, short circuit in wiring or poor connection between front climate control unit and driver-side front
POSSIBLE
air mix actuator
CAUSE
• Open, short circuit in wiring or poor connection between front climate control unit and passenger-side
front air mix actuator
• Open, short circuit in wiring or poor connection between front climate control unit and driver-side front
air mix actuator position sensor
• Open, short circuit in wiring or poor connection between front climate control unit and passenger-side
front air mix actuator position sensor
• Front climate control unit malfunction

07-03–22
1890-1U-06H(07-03).fm 23 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
Diagnostic procedure
STEP INSPECTION ACTION
1 CHECK SYMPTOM Yes Go to the next step.
• Turn on the front A/C. No Go to Step 8.
• Perform the dual A/C control function for
driver and passenger-side individually.
• Is it either of cannot the temperature control
on driver seat side or front passenger seat
side?
2 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN AIR MIX DOOR OR ELSEWHERE No Go to Step 6.
• Turn on the front A/C
• Change temperature control for suspect side
seat at the dual mode.
• Does the suspect side air mix door move
smoothly?
3 INSPECT AIR MIX DOOR Yes Go to the next step.
• Inspect the suspect side air mix door. No Remove the obstruction or replace the suspect side A/C unit
— Is the fan free of interfere with the suspect case, then go to Step 9.
side A/C unit case?
— Is the fan free of foreign material and
obstruction?
• Is the air mix door normal?
4 INSPECT FRONT AIR MIX ACTUATOR Yes Go to the next step.
• Inspect the suspect side front air mix 07-03
No Replace the suspect front air mix actuator, then go to Step
actuator. 9.
• Is the front air mix actuator normal?
5 INSPECT TO SEE WHETHER MALFUNCTION Yes Repair or replace malfunction part, then go to Step 9.
IS IN WIRING HARNESS (OPEN, SHORT OR No Replace the front climate control unit, then go to Step 9.
POOR CONNECTION OF TERMINALS
BETWEEN AIR MIX ACTUATOR AND FRONT
CLIMATE CONTROL UNIT) OR ELSEWHERE
• Inspect for open, short or poor connection of
terminals between the suspect front air mix
actuator and front climate control unit.
— Terminal 1A (front climate control unit)—
terminal G (driver-side front air mix
actuator)
— Terminal 1F (front climate control unit)—
terminal F (driver-side front air mix
actuator)
— Terminal 1E (front climate control unit)—
terminal F (passenger-side front air mix
actuator)
— Terminal 1C (front climate control unit)—
terminal G (passenger-side front air mix
actuator)
• Is there any open, short or poor connection
of terminals?
6* INSPECT FRONT AIR MIX ACTUATOR Yes Go to the next step.
POSITION SENSOR No Replace the suspect front air mix actuator position sensor,
• Inspect the suspect side front air mix then go to Step 9.
actuator position sensor.
• Is the front air mix actuator position sensor
normal?

07-03–23
1890-1U-06H(07-03).fm 24 ページ ２００６年１２月１９日　火曜日　午後１２時５５分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
7 INSPECT TO SEE WHETHER MALFUNCTION Yes Repair or replace malfunction part, then go to Step 9.
IS IN WIRING HARNESS (OPEN, SHORT OR No Replace the front climate control unit, then go to Step 9.
POOR CONNECTION OF TERMINALS
BETWEEN AIR MIX ACTUATOR POSITION
SENSOR AND FRONT CLIMATE CONTROL
UNIT) OR ELSEWHERE
• Inspect for open, short or poor connection of
terminals between the suspect front air mix
actuator position sensor and front climate
control unit.
— Terminal 2F (front climate control unit)—
terminal E (driver-side front air mix
actuator position sensor)
— Terminal 2G (front climate control unit)—
terminal E (passenger-side front air mix
actuator position sensor)
— Terminal 2B (front climate control unit)—
terminal A (each side front air mix
actuator position sensor)
— Terminal 2P (front climate control unit)—
terminal C (each side front air mix
actuator position sensor)
• Is there any open, short or poor connection
of terminals?
8 INSPECT TO SEE WHETHER MALFUNCTION Yes Repair or replace malfunction part, then go to the next step.
IS IN WIRING HARNESS (OPEN, SHORT OR No Replace the front climate control unit, then go to the step.
POOR CONNECTION OF TERMINALS
BETWEEN FRONT CLIMATE CONTROL UNIT
AND AIR MIX ACTUATOR POSITION
SENSOR) OR ELSEWHERE
• Inspect for open, short or poor connection of
terminals between the front climate control
unit and front air mix actuator position
sensor.
— Terminal 2B (front climate control unit)—
terminal A (each front air mix actuator
position sensor)
— Terminal 2P (front climate control unit)—
terminal C (each front air mix actuator
position sensor)
• Is there any open, short or poor connection
of terminals?
9 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Troubleshooting completed. Explain repairs to customer.
DOES NOT RECUR AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Does the temperature adjust individually for malfunction recurs.
driver seat and front passenger seat?

End Of Sie

07-03–24
1890-1U-06H(07-10).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時５６分

REFRIGERANT SYSTEM
07-10 REFRIGERANT SYSTEM
REFRIGERANT SYSTEM SERVICE Charging Recycled R-134a
WARNINGS . . . . . . . . . . . . . . . . . . . . . . 07-10–1 Refrigerant . . . . . . . . . . . . . . . . . . . . . 07-10–3
Handling Refrigerant . . . . . . . . . . . . . . 07-10–1 Charging Preparation . . . . . . . . . . . . . . 07-10–3
Storing Refrigerant. . . . . . . . . . . . . . . . 07-10–1 Evacuation. . . . . . . . . . . . . . . . . . . . . . . 07-10–3
REFRIGERANT SYSTEM SERVICE Airtightness Check . . . . . . . . . . . . . . . . 07-10–4
CAUTIONS . . . . . . . . . . . . . . . . . . . . . . 07-10–2 Charging New R-134a
Handling Insufficient Refrigerant . . . . . . . . . . . . . . . . . . . . . 07-10–4
Refrigerant Level . . . . . . . . . . . . . . . . 07-10–2 Leak Test. . . . . . . . . . . . . . . . . . . . . . . . 07-10–5
Handling A/C Related Parts . . . . . . . . . 07-10–2 REFRIGERANT RECOVERY . . . . . . . . . . 07-10–6
Handling Compressor Oil. . . . . . . . . . . 07-10–2 REFRIGERANT
REFRIGERANT SYSTEM GENERAL PRESSURE CHECK. . . . . . . . . . . . . . . . 07-10–6
PROCEDURES . . . . . . . . . . . . . . . . . . . 07-10–2 REFRIGERANT SYSTEM
Manifold Gauge Set Installation . . . . . . 07-10–2 PERFORMANCE TEST . . . . . . . . . . . . . 07-10–7
REFRIGERANT CHARGING. . . . . . . . . . 07-10–3

End of Toc
REFRIGERANT SYSTEM SERVICE WARNINGS
WM: REFRIGERANT SYSTEM

id071000800100
Handling Refrigerant
• Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and
throat. Also, due to environmental concerns, the use of recovery/recycling/recharging equipment is 07-10
mandatory when draining R-134a from the air conditioning system. If accidental system discharge
occurs, ventilate work area before resuming service.
• Do not perform pressure test or leak test for R-134a service equipment and/or vehicle air conditioning
system using compressed air. Some mixtures of air and R-134a have been shown to be combustible at
elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health
and safety information may be obtained from refrigerant manufacturers.
• Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if
the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any
operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources
and maintain adequate ventilation.
• Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When
handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes,
immediately wash them with clean water and consult a doctor.

Storing Refrigerant
• The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode,
scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at
temperatures below 40 °C {104 °F}.
End Of Sie

07-10–1
1890-1U-06H(07-10).fm 2 ページ ２００６年１２月１９日　火曜日　午後１２時５６分

REFRIGERANT SYSTEM
REFRIGERANT SYSTEM SERVICE CAUTIONS
id071000800200
Handling Insufficient Refrigerant Level
• If an insufficient refrigerant level is detected at troubleshooting, do not charge (add) the refrigerant.
Because an accurate amount of refrigerant cannot be determined from the pressure indicated on the
manifold gauge, never charge the refrigerant. If there is too much or too little refrigerant from the
refilling, there may be secondary problems such as damage to the refrigerant cycle parts, or a decrease
of cooling performance. Therefore, if it is determined that the refrigerant level is insufficient,
completely remove refrigerant from the refrigerant cycle and refill with refrigerant to the specified
amount.

Handling A/C Related Parts

• There will be no effect on either performance or quality of A/C-related parts, including but not limited to
the piping, etc., provided that said parts are serviced/repaired in accordance with standard procedure.
• When serviced/repaired A/C units in locations where there is a considerable risk of contamination from
dirt or dust, plug up the openings on the parts to prevent dust/dirt from entering.
• When using adhesive material to cover openings on A/C parts, make sure that the adhesive side of the
material does not come in contact with the connectors on the parts.
• When the system is opened to atmosphere, there is no need to replace the condenser, or the receiver
dryer when it is housed within the condenser, provided that the unit is plugged accordingly.

Handling Compressor Oil

• Use only DENSO OIL8 compressor oil for this vehicle. Using a PAG oil other than DENSO OIL8
compressor oil can damage the A/C compressor.
• Do not spill DENSO OIL8 compressor oil on the vehicle. A drop of compressor oil on the vehicle
surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately.
• DENSO OIL8 compressor oil (PAG oil) has a DENSO OIL8 COMPRESSOR OIL (PAG OIL)
higher moisture absorption efficiency than the
MOISTURE ABSORPTION

previously used mineral oil. If moisture mixes

with the compressor oil, the refrigerant
system could be damaged. Therefore, install
caps immediately after using the compressor
oil or removing refrigerant system parts to
prevent moisture absorption.
End Of Sie MINERAL OIL

0
TIME
am8rrw00000740

REFRIGERANT SYSTEM GENERAL PROCEDURES

id071000800300
Manifold Gauge Set Installation
1. Fully close the valves of the manifold gauge.
2. Connect the charging hoses to the high and low-
pressure side joints of the manifold gauge.
3. Connect the quick couplers to the ends of the
charging hoses.
4. Connect the quick couplers to the charging MANIFOLD GAUGE
valves.
End Of Sie CHARGING HOSE
WM: REFRIGERANT

QUICK COUPLER

CAP
CAP
CHARGING
CHARGING VALVE OF VALVE OF
LOW-PRESSURE SIDE HIGH-PRESSURE
SIDE

acxuuw00001560

07-10–2
1890-1U-06H(07-10).fm 3 ページ ２００６年１２月１９日　火曜日　午後１２時５６分

REFRIGERANT SYSTEM
REFRIGERANT CHARGING
id071000800400

Caution
• Do not exceed the specification when charging the system with refrigerant. Doing so will decrease
the efficiency of the air conditioner or damage the refrigeration cycle parts.

Charging Recycled R-134a Refrigerant

1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's
instructions.

Charging Preparation
1. Install the manifold gauge set.
2. Connect the tap pin side of the charging hose to the air purge valve of the manifold gauge.
3. Connect the vacuum pump hose to the center joint of the manifold gauge.
4. Connect the vacuum pump hose to the vacuum pump.
5. Connect the charging hose to the refrigerant tank.
6. Place the refrigerant tank on the scale. AIR PURGE VALVE
TAP PIN SIDE
MANIFOLD GAUGE
Regular amount of refrigerant (approx.
quantity)
660—710 g {23.3—25.0 oz} CHARGE HOSE VACUUM PUMP
HOSE
REFRIGERANT
TANK 07-10

SCALE

VACUUM PUMP
acxuuw00000768

Evacuation
1. Open all the valves of the manifold gauge.

Caution
• Close the manifold gauge valve immediately after stopping the vacuum pump. If the valve is left
open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in the
efficiency of the air conditioner.

2. Start the vacuum pump and let it operate for 15

MANIFOLD
min. GAUGE

CLOSE

acxuuw00000769

3. Verify that high- and low-pressure side readings

of the manifold gauge are at –101 kPa {–760 MANIFOLD
mmHg, –29.9 inHg}. Close each valve of the GAUGE
manifold gauge.

acxuuw00000770

07-10–3
1890-1U-06H(07-10).fm 4 ページ ２００６年１２月１９日　火曜日　午後１２時５６分

REFRIGERANT SYSTEM
Airtightness Check
1. Stop the vacuum pump and wait for 5 min.
2. Check the high- and low-pressure side readings of the manifold gauge.
• If the reading has changed, inspect for leakage and go to Evacuation. (See 07-10-3 Evacuation.)
• If the reading has not changed, go to Charging New R-134a Refrigerant. (See 07-10-4 Charging New R-
134a Refrigerant.)

Charging New R-134a Refrigerant

1. Open the valve of the refrigerant tank.
2. Weigh the refrigerant tank to charge the suitable amount of refrigerant.

Warning
• If the refrigerant system is charged with a large amount of refrigerant when inspecting for gas
leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In
order to prevent the accidental release of refrigerant which can destroy the ozone layer in the
stratosphere, follow the proper procedures and charge with only a small amount of refrigerant
when inspecting for gas leakage.
• If charging the system with refrigerant using service cans, running the engine with the high-
pressure side valve open is dangerous. Pressure within the service cans will increase and the
cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure
you. Therefore, do not open the high-pressure side valve while the engine is running.

Caution
• Always being charging of refrigerant from the high-pressure side. If changing is begun from the
low-pressure side, the vanes of the A/C compressor will not be released and abnormal noise may
result.

3. Open the high-pressure side valve of the manifold

gauge. MANIFOLD GAUGE

OPEN

acxuuw00000771

4. When the low-pressure side reading increases to

0.098 MPa {1.0 kgf/cm2, 14 psi}, close the high- MANIFOLD
GAUGE
pressure side valve of the manifold gauge.
5. Inspect for leakage from the cooler pipe/hose
connections using a gas leak tester.
• If there is no leakage, go to Step 7.
• If leakage is found at a loose joint, tighten the
joint, then go to the next step.
6. Inspect for leakage again.
• If there is no leakage after tightening the joint,
go to the next step.
• If there is still a leakage at the same joint, acxuuw00000772
discharge the refrigerant and then repair the
joint. Repeat the charging procedure from
evacuation.

Warning
• If charging the system with refrigerant using service cans, running the engine with the high-
pressure side valve open is dangerous. Pressure within the service cans will increase and the
cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure
you. Therefore, do not open the high-pressure side valve while the engine is running.

07-10–4
1890-1U-06H(07-10).fm 5 ページ ２００６年１２月１９日　火曜日　午後１２時５６分

REFRIGERANT SYSTEM
7. Open the high-pressure side valve of the manifold
gauge and charge with refrigerant until the weight MANIFOLD GAUGE
of refrigerant tank has decreased 330—355 g
{11.7—12.5 oz} from the amount in Step 2.

OPEN

acxuuw00000771

8. Close the low-pressure side valve of the manifold

gauge. MANIFOLD
GAUGE
Warning
• If charging the system with refrigerant
using service cans, running the engine
with the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
explode, scattering metal fragments and
liquid refrigerant that can seriously injure 07-10
you. Therefore, do not open the high-
acxuuw00000770
pressure side valve while the engine is
running.

9. Start the engine and actuate the A/C compressor.

10. Open the low-pressure side valve of the manifold
gauge and charge with refrigerant until the weight MANIFOLD GAUGE
of the refrigerant tank has decreased regular
amount from the amount in Step 2.
11. Close the low-pressure side valve of the manifold
gauge and the valve of the refrigerant tank. OPEN
12. Stop the engine and A/C compressor.

acxuuw00000773

Leak Test
1. Inspect for leakage using the a gas leak tester.
• If there is no leakage, go to Step 3.
• If leakage is found at a loose joint, tighten the joint, then go to the next step.
2. Inspect for leakage again.
• If there is no leakage after tightening the joint, go to the next step.
• If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the
charging procedure from evacuation.
3. Disconnect the manifold gauge from the charging valves.
4. Install the caps to the charging valves.
End Of Sie

CAP
CAP

acxuuw00000774

07-10–5
1890-1U-06H(07-10).fm 6 ページ ２００６年１２月２０日　水曜日　午前１０時１３分

REFRIGERANT SYSTEM
REFRIGERANT RECOVERY
id071000800500
1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer’s
instructions.
End Of Sie
REFRIGERANT PRESSURE CHECK
id071000800600
1. Connect the manifold gauge. (See 07-10-2 REFRIGERANT SYSTEM GENERAL PROCEDURES.)
2. Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
3. Set the fan speed MAX HI.
4. Turn the A/C switch on.
5. Set to RECIRCULATE mode.
6. Set the temperature control to MAX COLD.
7. Set to VENT mode.
8. Close all the doors and all the windows.
9. Measure the ambient temperature and high- and low-pressure side reading of the manifold gauge.
10. Verify that the intersection of the pressure reading of the manifold gauge and ambient temperature is in the
shaded zone.
• If there is any malfunction, inspect the PH
refrigerant system according to the (KPo)
troubleshooting chart. HI-PRESSURE
2.0
SIDE
End Of Sie
1.5
PRESSURE READING OF MANIHOLD GAUGE

PH 1.0
(KPo)
2.5
0.5
LOW-PRESSURE
{5.1, 73} SIDE
2.0

1.5

1.0

0.5
{5.1, 73} 10 20 30 40
{32} {68} {86} {104}
AMBIENT TEMPERATURE °C {°F}
ac9uuw00000831

07-10–6
1890-1U-06H(07-10).fm 7 ページ ２００６年１２月２０日　水曜日　午前１０時１３分

REFRIGERANT SYSTEM
REFRIGERANT SYSTEM PERFORMANCE TEST
id071000800700
1. Inspect the refrigerant pressure. (See 07-10-6 REFRIGERANT PRESSURE CHECK.)
2. Place a dry-bulb thermometer in the driver-side center ventilator outlet.
3. Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
4. Set the fan speed to MAX HI.
5. Turn the A/C switch on.
6. Set to RECIRCULATE mode.
7. Set the temperature control to MAX COLD.
8. Set to VENT mode.
9. Close all the doors and windows.
10. Wait until the air conditioner output temperature stabilizes.
Stabilized condition
• The A/C compressor repeatedly turns on and off at regular intervals.
11. After the blower air is stabilized, read the dry-bulb thermometer.
12. Verify the ambient temperature.
13. Verify that the temperature reading is in the
shaded zone. (°C {°F})
• If the there is any malfunction, inspect the

CENTER VENTILATOR
12{54}
refrigerant system according to the
10{50}
troubleshooting chart.
TEMP ERATURE
8{46}
End Of Sie 6{43}
4{39}
2{36}
07-10
0
10 20 30 40
{50} {68} {86} {104}
AMBIENT TEMPERATURE (°C {°F})
ac9uuw00000832

07-10–7
1890-1U-06H(07-11).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
07-11 BASIC SYSTEM
HVAC BASIC SYSTEM REAR HEAT DUCT COMPONENT
LOCATION INDEX. . . . . . . . . . . . . . . . . 07-11–2 REMOVAL/INSTALLATION . . . . . . . . . . 07-11–11
FRONT A/C UNIT Rear Heat Duct No.1 . . . . . . . . . . . . . . . 07-11–11
REMOVAL/INSTALLATION. . . . . . . . . . 07-11–3 Rear heat duct No.2 ,
FRONT A/C UNIT No.3 and No.4 . . . . . . . . . . . . . . . . . . . 07-11–11
DISASSEMBLY/ASSEMBLY . . . . . . . . . 07-11–6 REAR COOLER DUCT
FRONT EXPANSION VALVE REMOVAL/INSTALLATION . . . . . . . . . . 07-11–13
REMOVAL/INSTALLATION. . . . . . . . . . 07-11–7 A/C COMPRESSOR
AIR FILTER REMOVAL/INSTALLATION . . . . . . . . . . 07-11–14
REMOVAL/INSTALLATION. . . . . . . . . . 07-11–8 A/C Compressor
AIR FILTER INSPECTION. . . . . . . . . . . . 07-11–8 Installation Note . . . . . . . . . . . . . . . . . 07-11–14
FRONT EVAPORATOR CONDENSER
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-11–8 REMOVAL/INSTALLATION . . . . . . . . . . 07-11–15
FRONT HEATER CONDENSER INSPECTION . . . . . . . . . . 07-11–15
CORE INSPECTION . . . . . . . . . . . . . . . 07-11–8 HEATER PIPE AND HOSE COMPONENT
REAR A/C UNIT REMOVAL/INSTALLATION . . . . . . . . . . 07-11–15
REMOVAL/INSTALLATION. . . . . . . . . . 07-11–9 Heater Pipe and Hose
REAR A/C UNIT Installation Note . . . . . . . . . . . . . . . . . 07-11–17
DISASSEMBLY/ASSEMBLY . . . . . . . . . 07-11–10 REFRIGERANT LINE
REAR EVAPORATOR REMOVAL/INSTALLATION . . . . . . . . . . 07-11–17
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-11–10 Refrigerant Line Removal Note . . . . . . . 07-11–20 07-11
REAR HEATER Refrigerant Line Installation Note . . . . . 07-11–20
CORE INSPECTION . . . . . . . . . . . . . . . 07-11–11

End of Toc
WM: HVAC BASIC SYSTEM

07-11–1
1890-1U-06H(07-11).fm 2 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
HVAC BASIC SYSTEM LOCATION INDEX
id071100801700

2
3
5

13 14
7
8
12
9

10

11

ac9uuw00000777

1 Front A/C unit 3 Heater pipe and heater hose (front)

(See 07-11-3 FRONT A/C UNIT REMOVAL/ (See 07-11-15 HEATER PIPE AND HOSE
INSTALLATION.) COMPONENT REMOVAL/INSTALLATION.)
(See 07-11-6 FRONT A/C UNIT DISASSEMBLY/ 4 Rear heat duct No.1
ASSEMBLY.) (See 07-11-11 REAR HEAT DUCT COMPONENT
(See 07-11-8 AIR FILTER REMOVAL/ REMOVAL/INSTALLATION.)
INSTALLATION.)
(See 07-11-8 AIR FILTER INSPECTION.) 5 Refrigerant line (front)
(See 07-11-8 FRONT EVAPORATOR (See 07-11-17 REFRIGERANT LINE REMOVAL/
INSPECTION.) INSTALLATION.)
(See 07-11-8 FRONT HEATER CORE 6 A/C compressor
INSPECTION.) (See 07-11-14 A/C COMPRESSOR REMOVAL/
2 Front expansion valve INSTALLATION.)
(See 07-11-7 FRONT EXPANSION VALVE
REMOVAL/INSTALLATION.)

07-11–2
1890-1U-06H(07-11).fm 3 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
7 Condenser 10 Refrigerant line (rear)
(See 07-11-15 CONDENSER REMOVAL/ (See 07-11-17 REFRIGERANT LINE REMOVAL/
INSTALLATION.) INSTALLATION.)
(See 07-11-15 CONDENSER INSPECTION.) 11 Rear heat duct No.4
8 Rear A/C unit (See 07-11-11 REAR HEAT DUCT COMPONENT
(See 07-11-9 REAR A/C UNIT REMOVAL/ REMOVAL/INSTALLATION.)
INSTALLATION.) 12 Rear heat duct No.3
(See 07-11-10 REAR A/C UNIT DISASSEMBLY/ (See 07-11-11 REAR HEAT DUCT COMPONENT
ASSEMBLY.) REMOVAL/INSTALLATION.)
(See 07-11-10 REAR EVAPORATOR
INSPECTION.) 13 Rear heat duct No.2
(See 07-11-11 REAR HEATER CORE (See 07-11-11 REAR HEAT DUCT COMPONENT
INSPECTION.) REMOVAL/INSTALLATION.)
9 Heater pipe and heater hose (rear) 14 Rear cooler duct
(See 07-11-15 HEATER PIPE AND HOSE (See 07-11-13 REAR COOLER DUCT REMOVAL/
COMPONENT REMOVAL/INSTALLATION.) INSTALLATION.)

End Of Sie
FRONT A/C UNIT REMOVAL/INSTALLATION
WM: FRONT A/C UNIT

id071100802500
1. Disconnect the negative battery cable.
2. Discharge the refrigerant. (See 07-10-3 REFRIGERANT CHARGING.) 07-11
3. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
4. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(6) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(10)Front scuff plate inner (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(11)Front side trim (See 09-17-23 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(12)Glove compartment (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
(13)Hood release lever (See 09-14-46 HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)
(14)Lower panel (See 09-17-11 LOWER PANEL REMOVAL/INSTALLATION.)
(15)Lower column cover (See 09-17-8 COLUMN COVER REMOVAL/INSTALLATION.)
(16)Driver-side air bag module (See 08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
(17)Steering wheel (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(18)Combination switch (See 09-18-16 COMBINATION SWITCH REMOVAL/INSTALLATION.)
(19)Center panel (See 09-17-10 CENTER PANEL REMOVAL/INSTALLATION.)
(20)Meter hood (See 09-17-11 METER HOOD REMOVAL/INSTALLATION.)
(21)Instrument cluster (See 09-22-3 INSTRUMENT CLUSTER REMOVAL/INSTALLATION.)
(22)Audio unit (See 09-20-7 AUDIO UNIT REMOVAL/INSTALLATION.)
(23)Steering shaft (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(24)A-pillar trim (See 09-17-19 A-PILLAR TRIM REMOVAL/INSTALLATION.)
(25)Side panel (See 09-17-13 SIDE PANEL REMOVAL/INSTALLATION.)
5. Disconnect the front door wiring harness connector (Driver side). (See09-11-5 FRONT DOOR MODULE
REMOVAL/INSTALLATION.)
6. Remove the brake switch from the brake pedal with the brake switch connector connected. (See 04-11-4
BRAKE PEDAL REMOVAL/INSTALLATION.)
7. Remove the selector lever component. (See 05-18-8 SELECTOR LEVER COMPONENT REMOVAL/
INSTALLATION.)
8. Remove the windshield wiper arm. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/
INSTALLATION.)
9. Remove the cowl grille. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
10. Remove the windshield wiper motor. (See 09-19-4 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
11. Remove the dashboard. (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
12. Remove the rear heat duct fasteners and slide the rear heat duct rearward. (See 07-11-11 REAR HEAT DUCT
COMPONENT REMOVAL/INSTALLATION.)
13. Disconnect the drain hose.
07-11–3
1890-1U-06H(07-11).fm 4 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
14. Remove the nuts.
15. Remove the bracket. BOLT
16. Remove the bolts.
17. Remove the dashboard bracket. 8—12 N·m
{82—122 kgf·cm,
71—106 in·lbf}
NUT

BRACKET
BOLT DASHBOARD BRACKET
ac9uuw00000705

18. Remove the hose clips. FRONT HEATER HOSE NO.4

19. Remove the front heater hose No.3 and front
heater hose No.4. (See 07-11-15 HEATER PIPE HOSE CLIP
AND HOSE COMPONENT REMOVAL/
INSTALLATION.)

FRONT HEATER HOSE NO.3

ac9uuw00000706

20. Remove the front cooler pipe No.1 bracket

installation nut. FRONT COOLER PIPE
NO.1 BRACKET
INSTALLATION NUT
8—12 N·m {82—122 kgf·cm,
71—106 in·lbf}

ac9uuw00001047

21. Remove the nut.

22. Remove the front cooler pipe No.1 and front
cooler pipe No.4. (See 07-11-17 REFRIGERANT
FRONT COOLER
LINE REMOVAL/INSTALLATION.) PIPE NO.1
FRONT
Caution COOLER
• If moisture or foreign material enters the PIPE NO.4 R
NUT
refrigeration cycle, cooling ability will be 8—12 N·m
lowered and abnormal noise or other {82—122 kgf·cm,
71—106 in·lbf}
malfunction could occur. Always plug
open fittings immediately after removing
any refrigeration cycle parts.
ac9uuw00000952

07-11–4
1890-1U-06H(07-11).fm 5 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
23. Remove the nuts.
24. Remove the front A/C unit. Do not allow 8—12 N·m {82—122 kgf·cm,
NUT 71—106 in·lbf}
compressor oil to spill.
End Of Sie

FRONT A/C
UNIT
8—10 N·m {82—101 kgf·cm,
NUT 71—88 in·lbf}

ac9uuw00002296
07-11

07-11–5
1890-1U-06H(07-11).fm 6 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
FRONT A/C UNIT DISASSEMBLY/ASSEMBLY
id071100802400
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

34 15
32
33

43 39

29
35
28
42 1
37 2
40
6 7
9
30 31 27
41 26
36
18
38 21
3 8
20 25 19 11
8—12 N·m {82—122
kgf·cm, 71—106 in·lbf}
5
22
4
17
16
23
24
10
14
13

12
ac9uuw00000676

1 Adhesive polyurethane (1) 19 A/C case bracket (2)

2 Blower case (1) 20 Front heater core
3 Blower case cover (1) 21 Polyurethane foam (2)
4 Blower case cover (2) 22 Front expansion valve
5 Air filter 23 Front evaporator sensor
6 Air intake actuator 24 Front evaporator
7 Air intake link set 25 Harness (1)
8 Blower case (2) 26 Passenger-side front air mix actuator
9 Air intake door 27 Air mix link set
10 Harness (2) 28 Air hose
11 Front power MOS FET 29 Air hose duct
12 Front blower motor 30 Driver-side front air mix actuator
13 Grommet 31 Air mix link set
14 Drain hose 32 Front airflow mode actuator
15 Duct 33 Airflow mode link set
16 A/C case (4) 34 Polyurethane foam (3)
17 Blower case (3) 35 A/C case (2)
18 Polyurethane foam (1) 36 Passenger-side air mix door (1)

07-11–6
1890-1U-06H(07-11).fm 7 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
37 Passenger-side air mix door (2) 41 Driver-side air mix door (1)
38 A/C case (3) 42 Driver-side air mix door (2)
39 Front airflow mode door (2) 43 A/C case (1)
40 Front airflow mode door (1)

End Of Sie
FRONT EXPANSION VALVE REMOVAL/INSTALLATION
WM: EXPANSION VALVE

id071100802200
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07-10-6 REFRIGERANT RECOVERY.) (See 07-10-3
REFRIGERANT CHARGING.)
3. Remove the following parts:
(1) Windshield wiper blade (See .09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/
INSTALLATION)
(2) Cowl grille (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
(3) Windshield wiper motor (See 09-19-4 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
(4) Cowl panel (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
(5) Front cooler pipe No.1 bracket installation nut
FRONT COOLER PIPE
NO.1 BRACKET
INSTALLATION NUT
8—12 N·m {82—122 kgf·cm,
71—106 in·lbf} 07-11

ac9uuw00000709

(6) Nut
(7) Front cooler pipe No.1 and front cooler pipe
No.4 (See 07-11-17 REFRIGERANT LINE
FRONT COOLER
REMOVAL/INSTALLATION.) PIPE NO.1
FRONT
Caution COOLER
• If moisture or foreign material enters the PIPE NO.4 R
NUT
refrigeration cycle, cooling ability will be 8—12 N·m
lowered and abnormal noise or other {82—122 kgf·cm,
71—106 in·lbf}
malfunction could occur. Always plug
open fittings immediately after removing
any refrigeration cycle parts.
ac9uuw00000707

4. Remove the bolts.

5. Remove the front expansion valve. Do not allow
compressor oil to spill.
6. Install in the reverse order of removal.
7. Perform the refrigerant system performance test.
(See 07-10-7 REFRIGERANT SYSTEM FRONT EXPANSION
R VALVE
PERFORMANCE TEST.)
End Of Sie
WM: AIR FILTER

BOLT 3.43 N·m

{35.0 kgf·cm,
30.4 in·lbf}

ac9uuw00000710

07-11–7
1890-1U-06H(07-11).fm 8 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
AIR FILTER REMOVAL/INSTALLATION
id071100800700
1. Remove the glove compartment service hole
cover.
2. Remove the cover in the direction of the arrow.

GLOVE
COMPARTMENT COVER GLOVE
SERVICE HOLE COMPARTMENT
COVER
ac9uuw00000711

3. Remove the air filter in the direction of the arrow.

4. Install in the reverse order of removal.
End Of Sie

AIR FILTER
GLOVE
COMPARTMENT

ac9uuw00002029

AIR FILTER INSPECTION

id071100800800
1. Verify that there is no damage, excessive dirt, or abnormal odor on the air filter.
• If there is any malfunction, replace the air filter.

Note
• The air filter cannot be reused by cleaning it with water or compressed air.

End Of Sie
FRONT EVAPORATOR INSPECTION
WM: FRONT EVAPORATOR

id071100802100
1. Inspect the front evaporator for damage, cracks, and oil leakage.
• If there is any malfunction, replace the front evaporator.
2. Visually inspect the fins for bending.
• If there is any bending, use the end of a flathead screwdriver to straighten the fins.
End Of Sie
FRONT HEATER CORE INSPECTION
WM: FRONT HEATER CORE

id071100802300
1. Inspect the front heater core for damage, cracks, and water leakage.
• If there is any malfunction, replace the front heater core.
2. Visually inspect the fins for bending.
• If there is any bending, use the end of a flathead screwdriver to straighten the fins.
3. Visually inspect the heater hose for deformation.
• Repair with pliers if there is deformation. If there is any malfunction, replace the front heater core.
End Of Sie
WM: REAR A/C UNIT

07-11–8
1890-1U-06H(07-11).fm 9 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
REAR A/C UNIT REMOVAL/INSTALLATION
id071100802000
1. Disconnect the negative battery cable.
2. Evacuate the refrigerant from the system. (See 07-10-6 REFRIGERANT RECOVERY.) (See 07-10-3
REFRIGERANT CHARGING.)
3. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
4. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(6) Dashboard under cover (Passenger side) (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(10)Selector lever component (See 05-18-8 SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION.)
5. Remove the bolt.
6. Remove the rear cooler pipe No.1. Do not allow
compressor oil to spill.

Caution R R
• If moisture or foreign material enters the 07-11
refrigeration cycle, cooling ability will be REAR COOLER
lowered and abnormal noise will occur. PIPE NO.1
Always immediately plug open fittings
after removing any refrigeration cycle 8—12 N·m
parts to keep moisture or foreign material BOLT {82—112 kgf·cm,
71—106 in·lbf}
out of the cycle.
ac9uuw00000778

7. Jack up the vehicle.

8. Remove the hose clip.
9. Remove the rear heater hose No.1 and No.2.
REAR
REAR
HEATER
HEATER
HOSE NO.1
HOSE NO.2

HOSE
CLIP

ac9uuw00000779

10. Remove in the order indicated in the table .

1 Rear blower motor connector 6

2 Rear power MOS FET connector 2
3 Rear evaporator temperature sensor connector 1
7
4 Rear airflow mode actuator connector 6
5 Rear air mix actuator connector
6 Bolt
7 Rear A/C unit

11. Install in the reverse order of removal. 4 3

12. Perform the refrigerant system performance test. 6
(See 07-10-7 REFRIGERANT SYSTEM
PERFORMANCE TEST.) 5
End Of Sie
6 : 8—12 N·m {82—112 kgf·cm, 71—106 in·lbf}

ac9uuw00000780

07-11–9
1890-1U-06H(07-11).fm 10 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
REAR A/C UNIT DISASSEMBLY/ASSEMBLY
id071100801900
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

17
2
20

19
16
1

21
22 R
15 14

11

18 10
12

13 4
3

9
6 5
ac9uuw00000716

1 Rear blower motor 12 Rear heater core

2 Rear power MOS FET 13 Rear A/C case (3)
3 Rear air mix actuator 14 Rear expansion valve seal
4 Rear air mix link set 15 Rear expansion valve
5 Rear airflow mode actuator 16 Rear evaporator
6 Rear airflow mode link set 17 Rear A/C case (4)
7 Case bracket 18 Adhesive polyurethane
8 Rear evaporator temperature sensor 19 Rear A/C case (1)
9 Polyurethane foam 20 Rear A/C case (2)
10 Rear A/C case bracket 21 Air mix door
11 Bracket 22 Airflow mode door

End Of Sie
REAR EVAPORATOR INSPECTION
WM: REAR EVAPORATOR

id071100802600
1. Inspect for cracks, damage, and oil leakage.
• If any are found, replace the rear evaporator.
2. Inspect for bent fins.
• If any are bent, use a flathead screwdriver to straighten them.
End Of Sie
WM: REAR HEATER CORE

07-11–10
1890-1U-06H(07-11).fm 11 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
REAR HEATER CORE INSPECTION
id071100802900
1. Inspect for cracks, damage, and coolant leakage.
• If any are found, replace the rear heater core.
2. Inspect for bent fins.
• If any are bent, use a flathead screwdriver to straighten them.
3. Verify that the rear heater core inlet and outlet are not distorted or damaged.
• If they are distorted or damaged, repair then using pliers.
End Of Sie
REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION
WM: REAR HEAT DUCT

id071100802800
Rear Heat Duct No.1
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Front seat (See 09-13-3 FRONT SEAT REMOVAL/INSTALLATION.)
(2) Front scuff plate inner (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(3) Front side trim (See 09-17-23 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(4) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(5) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(6) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(7) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(8) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(9) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(10)Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
07-11
(11)Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(12)Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(13)Dust cover (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
3. Turn floor covering over. (See 09-17-33 FLOOR COVERING REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
1 Fastener 1
2 Rear heat duct No.1 (RH)
3 Rear heat duct No.1 (LH) 2
3
5. Install in the reverse order of removal.

ac9uuw00000781

Rear heat duct No.2 , No.3 and No.4

1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(6) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(10)Second-row seat (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
(11)Edge cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(12)Long slider cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(13)Third-row seat (See 09-13-22 THIRD-ROW SEAT REMOVAL/INSTALLATION.)
(14)Trunk box (See 09-17-29 TRUNK BOX REMOVAL/INSTALLATION.)
(15)Seat side box (See 09-17-29 SEAT SIDE BOX REMOVAL/INSTALLATION.)
(16)Trunk end trim (See 09-17-28 TRUNK END TRIM REMOVAL/INSTALLATION.)
(17)Third-row seat (See 09-13-22 THIRD-ROW SEAT REMOVAL/INSTALLATION.)
(18)Rear scuff plate inner (See 09-17-24 REAR SCUFF PLATE REMOVAL/INSTALLATION.)
(19)Third-row seat belt lower anchor installation bolt (See 08-11-5 THIRD-ROW SEAT BELT REMOVAL/
INSTALLATION.)
(20)Trunk side trim (See 09-17-27 TRUNK SIDE TRIM REMOVAL/INSTALLATION.)

07-11–11
1890-1U-06H(07-11).fm 12 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
3. Remove the two rear A/C unit retaining bolts on the rear side.
4. Turn floor covering over. (See 09-17-33 FLOOR COVERING REMOVAL/INSTALLATION.)
5. Remove the long slider. (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
6. Remove the fasteners.
7. Lift the rear side of the rear A/C unit and remove FASTENER
the rear heater duct No.2.
8. Remove the rear heat duct No.3.
9. Remove the rear heat duct No.4.
10. Install in the reverse order of removal.

REAR HEAT
REAR HEAT DUCT No.2
DUCT No.3

REAR HEAT
DUCT No.4
ac9uuw00001142

When removing the rear heater duct No.3 only

1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Second-row seat (LH) (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
(2) Edge cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(3) Long slider cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
3. Cut away the floor covering as shown in the
figure.
FRONT
Note
• The cut part does not need to match up CUTTING
when installing the floor covering. LINE

REAR HEAT
DUCT No.3
ac9uuw00000782

4. Turn floor covering over.

5. Remove the rear heat duct No.3. FLOOR COVERING
6. Install in the reverse order of removal.

REAR HEAT
DUCT NO.3

ac9uuw00000783

07-11–12
1890-1U-06H(07-11).fm 13 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
When removing the rear heater duct No.4 only
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Second-row seat (RH) (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
(2) Edge cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
(3) Long slider cover (See 09-13-22 LONG SLIDER REMOVAL/INSTALLATION.)
3. Cut away the floor covering as shown in the
figure.

Note FRONT
• The cut part does not need to match up
when installing the floor covering.
REAR HEAT
DUCT NO.4

CUTTING
LINE
ac9uuw00000953

4. Turn floor covering over.

5. Remove the rear heat duct No.4. FLOOR COVERING
6. Install in the reverse order of removal.
End Of Sie REAR HEAT
WM: REAR COOLER DUCT

DUCT NO.4
07-11

ac9uuw00000954

REAR COOLER DUCT REMOVAL/INSTALLATION

id071100803100
1. Disconnect the negative battery cable.
2. Remove the console cover. (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
3. Remove the screws. REAR COOLER DUCT
4. Remove the rear cooler duct.
5. Install in the reverse order of removal.
End Of Sie
WM: A/C COMPRESSOR

SCREW

CONSOLE COVER
ac9uuw00000506

07-11–13
1890-1U-06H(07-11).fm 14 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
A/C COMPRESSOR REMOVAL/INSTALLATION
id071100801000
1. Disconnect the negative battery cable.
2. Discharge the refrigerant. (See 07-10-3 REFRIGERANT CHARGING.)
3. Remove the drive belt. (See 01-10-4 DRIVE BELT REMOVAL/INSTALLATION [MZI-3.5].)
4. Remove the front cooler hose (Hi). (See 07-11-17 REFRIGERANT LINE REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table. Do not allow compressor oil to spill.

Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise or other malfunction could occur. Always plug open fittings immediately after
removing any refrigeration cycle parts.

1 Front cooler hose (LO)

4 3 R
(See 07-11-17 REFRIGERANT LINE REMOVAL/ 1
INSTALLATION.)
2 Front cooler pipe No.2 R
(See 07-11-17 REFRIGERANT LINE REMOVAL/
INSTALLATION.)
3 A/C compressor connector
4 A/C compressor 2
(See 07-11-14 A/C Compressor Installation Note.)
24—36 N·m
{2.5—3.6 kgf·m,
6. Install in the reverse order of removal. 18—26 ft·lbf}
7. Perform the refrigerant system performance test. ac9uuw00000956
(See 07-10-7 REFRIGERANT SYSTEM
PERFORMANCE TEST.)

A/C Compressor Installation Note

Caution
• Due to the high moisture-absorption characteristics of the compressor oil, it may absorb moisture
if left over a long period of time thereby negatively affecting A/C operation. Drain the compressor
oil and refill within 10 min. of each other.

1. Rotate new A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a clean measuring
device. Use this refrigerant oil to refill new compressor. Do not allow refrigerant oil to become contaminated.
2. Rotate old A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a separate, clean
measuring device.
3. Compare those oil amounts. The amount of the oil drained from the new A/C compressor should be greater
than the old one.
4. Pour the same amount oil of drained from the old
A/C compressor back into the new A/C NEW A/C COMPRESSOR OLD A/C COMPRESSOR
compressor.

A/C compressor oil type

• DENSO OIL8

A/C compressor oil sealed volume (approx. SAME

quantity) AMOUNT
• 160 ml {160 cc, 5.41 fl oz}

End Of Sie
WM: CONDENSER

am8rrw00000755

07-11–14
1890-1U-06H(07-11).fm 15 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATION
id071100801200
1. Disconnect the negative battery cable.
2. Discharge the refrigerant. (See 07-10-3 REFRIGERANT CHARGING.)
3. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
4. Remove the air cleaner and fresh air duct component. (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION [MZI-3.5].)
5. Remove the cooling fan component. (See 01-12-14 FAN MOTOR REMOVAL/INSTALLATION [MZI-3.5].)
6. Disconnect the ATF oil cooler hose from the radiator.
7. Remove the radiator. (See 01-12-8 RADIATOR REMOVAL/INSTALLATION [MZI-3.5].)
8. Remove the nut and disconnect front cooler pipes No.3 and No.4. (See 07-11-17 REFRIGERANT LINE
REMOVAL/INSTALLATION.)
9. Remove the front cooler pipe No.3 bracket. (See 07-11-17 REFRIGERANT LINE REMOVAL/INSTALLATION.)
10. Remove the bolts and two condenser brackets.
11. Remove in the order indicated in the table. Do not allow remaining compressor oil in the refrigerant line to spill.

Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise or other malfunction could occur. Always plug open fittings immediately after
removing any refrigeration cycle parts.

1 Front cooler hose (HI) 1

A CONDENSER BRACKET
(See 07-11-17 REFRIGERANT LINE REMOVAL/ R
INSTALLATION.) 07-11
2 Front cooler pipe No.3
(See 07-11-17 REFRIGERANT LINE REMOVAL/ 2
INSTALLATION.)
3 Condenser
3
12. Install in the reverse order of removal. R
A
13. Refill the engine coolant. (See 01-12-5 ENGINE
COOLANT REPLACEMENT [MZI-3.5].)
14. Inspect for engine coolant leakage. (See 01-12-6
ENGINE COOLANT LEAKAGE INSPECTION
[MZI-3.5].)
15. Inspect the ATF level. (See 05-17-11
AUTOMATIC TRANSAXLE FLUID (ATF)
A: 8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}
INSPECTION [AW6A-EL, AW6AX-EL].)
16. Perform the refrigerant system performance test. ac9uuw00001048
(See 07-10-7 REFRIGERANT SYSTEM
PERFORMANCE TEST.)
End Of Sie
CONDENSER INSPECTION
id071100801300
1. Inspect the condenser for cracks, damage, and oil leakage.
• If there is any malfunction, replace the condenser.
2. Visually inspect the fins for clogging of foreign material.
• If any fins are clogged, remove the foreign material.
3. Visually inspect the fins for bending.
• If there is any bending, use the end of a flathead screwdriver to straighten fins.
End Of Sie
HEATER PIPE AND HOSE COMPONENT REMOVAL/INSTALLATION
WM: HEATER PIPES AND HOSES

id071100802700
1. Remove the battery. (See 01-17-2 BATTERY REMOVAL/INSTALLATION [MZI-3.5].)
2. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
3. Remove the following parts:
(1) Windshield wiper arm and blade. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/
INSTALLATION.)
(2) Cowl grille (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
(3) Windshield wiper motor (See 09-19-4 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
(4) Cowl panel (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)

07-11–15
1890-1U-06H(07-11).fm 16 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
4. Remove in the order indicated in the table. NUT
1 7
1 Front heater hose No.4
(See 07-11-17 Heater Pipe and Hose Installation
Note.) 5
2 Front heater hose No.3
(See 07-11-17 Heater Pipe and Hose Installation
Note.) NUT
3 Front heater hose No.6 4
3
(See 07-11-17 Heater Pipe and Hose Installation 2
Note.) 6
NUT: 8—12 N·m
4 Front heater hose No.5 {82—122 kgf·cm, 71—106 in·lbf}
(See 07-11-17 Heater Pipe and Hose Installation ac9uuw00000959
Note.)
5 Front heater hose No.2
(See 07-11-17 Heater Pipe and Hose Installation
Note.)
6 Front heater hose No.1
(See 07-11-17 Heater Pipe and Hose Installation
Note.)
7 Front heater pipe
(See 07-11-17 Heater Pipe and Hose Installation
Note.)

5. Jack up the vehicle.

6. Under guard (LH) (See 01-16-5 CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID VALVE, AIR
FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.5]

FRONT

CLIP

BOLT
8—12 N·m
{82—122 kgf·cm,
3 71—106 in·lbf}

ac9uuw00000960

1 Front heater hose No.1 3 Front heater pipe

(See 07-11-17 Heater Pipe and Hose Installation (See 07-11-17 Heater Pipe and Hose Installation
Note.) Note.)
2 Front heater hose No.2
(See 07-11-17 Heater Pipe and Hose Installation
Note.)

07-11–16
1890-1U-06H(07-11).fm 17 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
7. Install in the reverse order of removal.
8. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5].)

Heater Pipe and Hose Installation Note

• Insert the heater pipe into the heater hose until
the hose reaches the bracket or the protrusion on
the pipe.
• When the rear heater pipe is removed, bleed the
air from the rear heater pipe thoroughly after
refilling the engine coolant to prevent air from RIGHT RIGHT
being trapped in the rear heater pipe.
End Of Sie
WM: REFRIGERANT LINES

WRONG WRONG
am8rrw00001897

REFRIGERANT LINE REMOVAL/INSTALLATION

id071100803000
1. Disconnect the negative battery cable.
2. Discharge the refrigerant. (See 07-10-3 REFRIGERANT CHARGING.)
3. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT [MZI-3.5].)
4. Remove the following parts:
(1) Windshield wiper arm and blade (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/ 07-11
INSTALLATION.)
(2) Cowl grille (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
(3) Windshield wiper motor (See 09-19-4 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
(4) Cowl panel (See 09-10-14 COWL PANEL REMOVAL/INSTALLATION.)
(5) Air cleaner and fresh air duct component (See 01-13-4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
[MZI-3.5].)
(6) Cooling fan component (See 01-12-14 FAN MOTOR REMOVAL/INSTALLATION [MZI-3.5].)
5. Disconnect the ATF oil cooler hose from the radiator.
6. Remove the radiator (See 01-12-8 RADIATOR REMOVAL/INSTALLATION [MZI-3.5].)
7. Remove the condenser. (See 07-11-15 CONDENSER REMOVAL/INSTALLATION.)
8. Remove the coolant reserve tank retaining bolts and move the coolant reserve tank.
9. Remove the power steering oil pump retaining bolt and nut and move the power steering oil pump. (See 06-14-
20 POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)
10. Do not allow remaining compressor oil in the piping and connecting parts to spill, and remove in the order
indicated in the table.

Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise or other malfunction could occur. Always plug open fittings immediately after
removing any refrigeration cycle parts.

07-11–17
1890-1U-06H(07-11).fm 18 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM

6
A

A
R
R
CLIP

5
A
R 2 A
4
A

1
R
A
R
A
B

B
3
A

A: 8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}

ac9uuw00000973
.

1 Front cooler pipe No.3 4 Front cooler pipe No.2

(See 07-11-20 Refrigerant Line Removal Note.) (See 07-11-20 Refrigerant Line Removal Note.)
(See 07-11-20 Refrigerant Line Installation Note.) (See 07-11-20 Refrigerant Line Installation Note.)
2 Front cooler hose (LO) 5 Front cooler pipe No.1
(See 07-11-20 Refrigerant Line Removal Note.) (See 07-11-20 Refrigerant Line Removal Note.)
(See 07-11-20 Refrigerant Line Installation Note.) (See 07-11-20 Refrigerant Line Installation Note.)
3 Front cooler hose (HI) 6 Front cooler pipe No.4
(See 07-11-20 Refrigerant Line Removal Note.) (See 07-11-20 Refrigerant Line Removal Note.)
(See 07-11-20 Refrigerant Line Installation Note.) (See 07-11-20 Refrigerant Line Installation Note.)

11. Remove the following parts, depending on rear cooler pipe to be removed.
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(6) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(10)Front seat (passenger side) (See 09-13-3 FRONT SEAT REMOVAL/INSTALLATION.)

07-11–18
1890-1U-06H(07-11).fm 19 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
(11)Bolt
(12)Screws
(13)Rear cooler pipe No.1 bracket.
12. Jack up the vehicle.
R R
SCREW

BOLT
8—12 N·m
{82—122 kgf·cm,
71—106 in·lbf}

REAR COOLER REAR COOLER

PIPE NO.1 PIPE NO.1
BRACKET

ac9uuw00000974

13. Remove the nuts and disconnect the presilencer

UNDER MIDDLE PIPE RUBBER
and middle pipe.
GUARD (RH) HANGER
14. Disconnect the rubber hanger.
15. Remove the bolts and presilencer insulator. PRESILENCER
16. Remove the bolts. INSULATOR 07-11
17. Remove the nut and fastener.
18. Remove the under guard (RH).
19. Remove the transverse member retaining bolts
and set the transverse member out of the way.
(See 02-13-15 TRANSVERSE MEMBER
REMOVAL/INSTALLATION.)
BOLT FASTENER
8—10
{82—101, PRESILENCER BOLT
71—88 } NUT
8—10 8—10
{82—101, {82—101,
71—88 } 71—88 }
N·m {kgf·cm, in·lbf}

ac9uuw00001016

20. Remove the bolt.

21. Remove the clip.
22. Disconnect rear cooler pipe No.1 and remove rear
cooler pipes No.2 and No.1.
23. Install in the reverse order of removal.
24. Inspect for engine coolant leakage. (See 01-12-6
ENGINE COOLANT LEAKAGE INSPECTION
[MZI-3.5].) REAR
25. Inspect the ATF level. (See 05-17-11 FRONT
COOLER
AUTOMATIC TRANSAXLE FLUID (ATF) PIPE NO.2
INSPECTION [AW6A-EL, AW6AX-EL].) 8—12 N·m BOLT
26. Perform the refrigerant system performance test. {82—122 kgf·cm, 71—106 in·lbf} CLIP
ac9uuw00001017
(See 07-10-7 REFRIGERANT SYSTEM
PERFORMANCE TEST.)

07-11–19
1890-1U-06H(07-11).fm 20 ページ ２００６年１２月１９日　火曜日　午後１２時５８分

BASIC SYSTEM
Refrigerant Line Removal Note
Block joint type
1. Disconnect the block joint type pipes by grasping MALE SIDE BLOCK FEMALE SIDE HOLD FIRMLY THE FEMALE
the female side of the block with pliers or similar BLOCK SIDE OF THE BLOCK USING
tool and holding firmly, and then remove the PLIERS OR EQUIVALENT.
connection bolt or nut.

TORQUE WRENCH
am8rrw00000760

Refrigerant Line Installation Note

1. Temporarily tighten the joint bolt by hand.
2. Connect the block joint type pipes by grasping the MALE SIDE BLOCK
FEMALE SIDE HOLD FIRMLY THE FEMALE
female side of the block with pliers or similar tool BLOCK SIDE OF THE BLOCK USING
and holding firmly, and then tighten the PLIERS OR EQUIVALENT.
connection bolt or nut with a torque wrench.
End Of Sie

am8rrw00000763

07-11–20
1890-1U-06H(07-40).fm 1 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
07-40 CONTROL SYSTEM
HVAC CONTROL SYSTEM MAGNETIC CLUTCH
LOCATION INDEX. . . . . . . . . . . . . . . . . 07-40–2 DISASSEMBLY/ASSEMBLY . . . . . . . . . 07-40–15
AIR INTAKE ACTUATOR Snap Ring Installation Note. . . . . . . . . . 07-40–16
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–4 MAGNETIC CLUTCH
AIR INTAKE ACTUATOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 07-40–16
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–4 MAGNETIC CLUTCH
FRONT AIR MIX ACTUATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–17
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–5 SOLAR RADIATION SENSOR
Driver Side . . . . . . . . . . . . . . . . . . . . . . 07-40–5 REMOVAL/INSTALLATION . . . . . . . . . . 07-40–17
Passenger Side . . . . . . . . . . . . . . . . . . 07-40–5 SOLAR RADIATION SENSOR
FRONT AIR MIX ACTUATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–17
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–6 AMBIENT TEMPERATURE SENSOR
Driver Side . . . . . . . . . . . . . . . . . . . . . . 07-40–6 REMOVAL/INSTALLATION . . . . . . . . . . 07-40–18
Passenger Side . . . . . . . . . . . . . . . . . . 07-40–7 AMBIENT TEMPERATURE SENSOR
REAR AIR MIX ACTUATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–18
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–7 CABIN TEMPERATURE SENSOR
REAR AIR MIX ACTUATOR REMOVAL/INSTALLATION . . . . . . . . . . 07-40–19
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–8 CABIN TEMPERATURE SENSOR
FRONT AIRFLOW MODE ACTUATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–19
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–9 FRONT EVAPORATOR TEMPERATURE
FRONT AIRFLOW MODE ACTUATOR SENSOR 07-40
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–10 REMOVAL/INSTALLATION . . . . . . . . . . 07-40–19
REAR AIRFLOW MODE ACTUATOR FRONT EVAPORATOR TEMPERATURE
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–10 SENSOR INSPECTION . . . . . . . . . . . . . 07-40–20
REAR AIRFLOW MODE ACTUATOR REAR EVAPORATOR TEMPERATURE
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–11 SENSOR
FRONT BLOWER MOTOR REMOVAL/INSTALLATION . . . . . . . . . . 07-40–21
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–12 REAR EVAPORATOR TEMPERATURE
FRONT BLOWER MOTOR SENSOR INSPECTION . . . . . . . . . . . . . 07-40–21
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–12 REFRIGERANT PRESSURE SWITCH
REAR BLOWER MOTOR REMOVAL/INSTALLATION . . . . . . . . . . 07-40–22
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–12 Refrigerant Pressure Switch
REAR BLOWER MOTOR Installation Note . . . . . . . . . . . . . . . . . 07-40–22
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–13 REFRIGERANT PRESSURE
FRONT POWER METAL OXIDE SWITCH INSPECTION . . . . . . . . . . . . . . 07-40–22
SEMICONDUCTOR FIELD EFFECT FRONT CLIMATE CONTROL UNIT
TRANSISTOR (POWER MOS FET) REMOVAL/INSTALLATION . . . . . . . . . . 07-40–23
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–13 FRONT CLIMATE CONTROL UNIT
FRONT POWER METAL OXIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–23
SEMICONDUCTOR FIELD EFFECT Terminal Voltage Table
TRANSISTOR (POWER MOS FET) (Reference) . . . . . . . . . . . . . . . . . . . . . 07-40–23
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–14 REAR CLIMATE CONTROL UNIT
REAR POWER METAL OXIDE REMOVAL/INSTALLATION . . . . . . . . . . 07-40–30
SEMICONDUCTOR FIELD EFFECT REAR CLIMATE CONTROL UNIT
TRANSISTOR (POWER MOS FET) INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–30
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–14 Terminal voltage table
REAR POWER METAL OXIDE (Reference) . . . . . . . . . . . . . . . . . . . . . 07-40–30
SEMICONDUCTOR FIELD EFFECT
TRANSISTOR (POWER MOS FET)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–15

End of Toc
WM: HVAC CONTROL SYSTEM

07-40–1
1890-1U-06H(07-40).fm 2 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
HVAC CONTROL SYSTEM LOCATION INDEX
id074000803600

FRONT

4 6 8
7

5
3

9
10
11
12

13

14
15

16
22 23

21

20 24

17 19
18
ac9uuw00001631

1 Refrigerant pressure switch 3 Magnetic clutch

(See 07-40-22 REFRIGERANT PRESSURE (See 07-40-15 MAGNETIC CLUTCH
SWITCH REMOVAL/INSTALLATION.) DISASSEMBLY/ASSEMBLY.)
(See 07-40-22 REFRIGERANT PRESSURE (See 07-40-16 MAGNETIC CLUTCH
SWITCH INSPECTION.) ADJUSTMENT.)
2 Ambient temperature sensor (See 07-40-17 MAGNETIC CLUTCH
(See 07-40-18 AMBIENT TEMPERATURE INSPECTION.)
SENSOR REMOVAL/INSTALLATION.) 4 Front blower relay
(See 07-40-18 AMBIENT TEMPERATURE (See 09-21-6 RELAY INSPECTION.)
SENSOR INSPECTION.) 5 Rear window defroster relay
(See 09-21-6 RELAY INSPECTION.)
6 A/C relay
(See 09-21-6 RELAY INSPECTION.)

07-40–2
1890-1U-06H(07-40).fm 3 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
7 Rear blower relay 17 Rear airflow mode actuator
(See 09-21-6 RELAY INSPECTION.) (See 07-40-10 REAR AIRFLOW MODE
8 Seat warmer relay ACTUATOR REMOVAL/INSTALLATION.)
(See 09-21-6 RELAY INSPECTION.) (See 07-40-11 REAR AIRFLOW MODE
ACTUATOR INSPECTION.)
9 Solar radiation sensor
(See 07-40-17 SOLAR RADIATION SENSOR 18 Rear air mix actuator
REMOVAL/INSTALLATION.) (See 07-40-7 REAR AIR MIX ACTUATOR
(See 07-40-17 SOLAR RADIATION SENSOR REMOVAL/INSTALLATION.)
INSPECTION.) (See 07-40-8 REAR AIR MIX ACTUATOR
INSPECTION.)
10 Front airflow mode actuator
(See 07-40-9 FRONT AIRFLOW MODE 19 Rear evaporator temperature sensor
ACTUATOR REMOVAL/INSTALLATION.) (See 07-40-21 REAR EVAPORATOR
(See 07-40-10 FRONT AIRFLOW MODE TEMPERATURE SENSOR REMOVAL/
ACTUATOR INSPECTION.) INSTALLATION.)
(See 07-40-21 REAR EVAPORATOR
11 Front evaporator temperature sensor TEMPERATURE SENSOR INSPECTION.)
(See 07-40-19 FRONT EVAPORATOR
TEMPERATURE SENSOR REMOVAL/ 20 Rear power MOS FET
INSTALLATION.) (See 07-40-14 REAR POWER METAL OXIDE
(See 07-40-20 FRONT EVAPORATOR SEMICONDUCTOR FIELD EFFECT TRANSISTOR
TEMPERATURE SENSOR INSPECTION.) (POWER MOS FET) REMOVAL/INSTALLATION.)
(See 07-40-15 REAR POWER METAL OXIDE
12 Air intake actuator SEMICONDUCTOR FIELD EFFECT TRANSISTOR
(See 07-40-4 AIR INTAKE ACTUATOR REMOVAL/ (POWER MOS FET) INSPECTION.)
INSTALLATION.)
(See 07-40-4 AIR INTAKE ACTUATOR 21 Rear blower motor
(See 07-40-12 REAR BLOWER MOTOR 07-40
INSPECTION.)
REMOVAL/INSTALLATION.)
13 Front power MOS FET (See 07-40-12 FRONT BLOWER MOTOR
(See 07-40-13 FRONT POWER METAL OXIDE INSPECTION.)
SEMICONDUCTOR FIELD EFFECT TRANSISTOR
(POWER MOS FET) REMOVAL/INSTALLATION.) 22 Passenger-side front air mix actuator
(See 07-40-14 FRONT POWER METAL OXIDE (See 07-40-5 FRONT AIR MIX ACTUATOR
SEMICONDUCTOR FIELD EFFECT TRANSISTOR REMOVAL/INSTALLATION.)
(POWER MOS FET) INSPECTION.) (See 07-40-6 FRONT AIR MIX ACTUATOR
INSPECTION.)
14 Cabin temperature sensor
(See 07-40-19 CABIN TEMPERATURE SENSOR 23 Front blower motor
REMOVAL/INSTALLATION.) (See 07-40-12 FRONT BLOWER MOTOR
(See 07-40-19 CABIN TEMPERATURE SENSOR REMOVAL/INSTALLATION.)
INSPECTION.) (See 07-40-12 FRONT BLOWER MOTOR
INSPECTION.)
15 Driver-side front air mix actuator
(See 07-40-5 FRONT AIR MIX ACTUATOR 24 Front climate control unit
REMOVAL/INSTALLATION.) (See 07-40-23 FRONT CLIMATE CONTROL UNIT
(See 07-40-6 FRONT AIR MIX ACTUATOR REMOVAL/INSTALLATION.)
INSPECTION.) (See 07-40-23 FRONT CLIMATE CONTROL UNIT
INSPECTION.)
16 Rear climate control unit
(See 07-40-30 REAR CLIMATE CONTROL UNIT
REMOVAL/INSTALLATION.)
(See 07-40-30 REAR CLIMATE CONTROL UNIT
INSPECTION.)

End Of Sie
WM: AIR INTAKE ACTUATOR

07-40–3
1890-1U-06H(07-40).fm 4 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
AIR INTAKE ACTUATOR REMOVAL/INSTALLATION
id074000801400
1. Disconnect the negative battery cable.
2. Remove the dashboard under cover. (Passenger side) (See 09-17-14 DASHBOARD UNDER COVER
REMOVAL/INSTALLATION.)
3. Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
4. Insert a flathead screwdriver as shown in the
figure and detach the fuse block tab by prying it in
the direction of the arrow. TAB
5. Press the fuse block and remove it from the
bracket.
6. Set the fuse block out of the way.

TAB

FUSE BLOCK
ac9uuw00001119

7. Remove in the order indicated in the table.

1 Air intake actuator connector
2 Screw
3
3 Air intake actuator

8. Install in the reverse order of removal. 1

2
End Of Sie

ac9uuw00000656

AIR INTAKE ACTUATOR INSPECTION

id074000801500
1. Connect battery positive voltage to air intake actuator terminal G, connect terminal A (or C) to ground, and then
verify that the air intake actuator operates as shown in the table.
• If the operation condition is not normal, replace the air intake actuator.
9°—21°
FRESH

RECIRCULATE
12°—18°
ac9uuw00002292

Terminal Air intake actuator

A C G operation G * * * C * A
Ground – B+ RECIRCULATE → FRESH
– Ground B+ FRESH → RECIRCULATE C

A
End Of Sie
WM: FRONT AIR MIX ACTUATOR

M G

ac9uuw00001104

07-40–4
1890-1U-06H(07-40).fm 5 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
FRONT AIR MIX ACTUATOR REMOVAL/INSTALLATION
id074000805800
Driver Side
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Dashboard under cover (Driver side) (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
(2) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(3) Console panel (LH) (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(4) Hood release lever (See 09-14-46 HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)
(5) Lower panel (See 09-17-11 LOWER PANEL REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
1 Driver-side front air mix actuator connector
2 Screw
3 Driver-side front air mix actuator
3
4. Install in the reverse order of removal.
2

ac9uuw00000657
07-40

Passenger Side
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(6) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(10)Front scuff plate inner (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(11)Front side trim (See 09-17-23 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(12)Glove compartment (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
(13)Hood release lever (See 09-14-46 HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)
(14)Lower panel (See 09-17-11 LOWER PANEL REMOVAL/INSTALLATION.)
(15)Lower column cover (See 09-17-8 COLUMN COVER REMOVAL/INSTALLATION.)
(16)Driver-side air bag module (See 08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
(17)Steering wheel (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(18)Combination switch (See 09-18-16 COMBINATION SWITCH REMOVAL/INSTALLATION.)
(19)Center panel (See 09-17-10 CENTER PANEL REMOVAL/INSTALLATION.)
(20)Meter hood (See 09-17-11 METER HOOD REMOVAL/INSTALLATION.)
(21)Instrument cluster (See 09-22-3 INSTRUMENT CLUSTER REMOVAL/INSTALLATION.)
(22)Audio unit (See 09-20-7 AUDIO UNIT REMOVAL/INSTALLATION.)
(23)Steering shaft (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(24)A-pillar trim (See 09-17-19 A-PILLAR TRIM REMOVAL/INSTALLATION.)
(25)Side panel (See 09-17-13 SIDE PANEL REMOVAL/INSTALLATION.)
3. Disconnect the front door wiring harness connector (Driver side). (See09-11-5 FRONT DOOR MODULE
REMOVAL/INSTALLATION.)
4. Disconnect the dashboard harness connectors.
5. Remove the brake switch from the brake pedal with the brake switch connector connected. (See 04-11-4
BRAKE PEDAL REMOVAL/INSTALLATION.)
6. Remove the selector lever component. (See 05-18-8 SELECTOR LEVER COMPONENT REMOVAL/
INSTALLATION.)
7. Remove the windshield wiper arm and blade. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION.)
8. Remove the cowl grille. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
9. Remove the windshield wiper motor. (See 09-19-4 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
10. Remove the dashboard. (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)

07-40–5
1890-1U-06H(07-40).fm 6 ページ ２００６年１２月２０日　水曜日　午前１０時２９分

CONTROL SYSTEM
11. Remove in the order indicated in the table.
1 Passenger-side front air mix actuator connector
2 Screw
3 Passenger-side front air mix actuator

12. Install in the reverse order of removal. 3

End Of Sie

ac9uuw00001040

FRONT AIR MIX ACTUATOR INSPECTION

id074000805700
Driver Side
1. Connect battery positive voltage to front air mix actuator terminal F (or G), connect terminal G (or F) to ground,
and then verify that the front air mix actuator operates as shown in the table.
• If the operation condition is not normal, replace the front air mix actuator.
Terminal Front air mix actuator
F G operation
F
B+ Ground HOT → COLD
Ground B+ COLD → HOT G F E D C B A

G
MAX HOT MAX COLD
A
E
C

ac9uuw00002424

9°—15°MAX COLD
60°

MAX HOT

am8rrw00001844

2. Verify that the resistance between terminals A

BETWEEN A AND E BETWEEN E AND C
and E, and E and C matches the front air mix KILOHM
TERMINALS WIRE TERMINALS WIRE
actuator operation as shown in the graph. 4.8
• If the operation condition and resistance are
RESISTANCE

not normal, replace the front air mix actuator.

1.2

MAX MAX MAX MAX

COLD HOT COLD HOT
FRONT AIR MIX ACTUATOR POSITION
am8rrw00000833

07-40–6
1890-1U-06H(07-40).fm 7 ページ ２００６年１２月２０日　水曜日　午前１０時２９分

CONTROL SYSTEM
Passenger Side
1. Connect battery positive voltage to front air mix actuator terminal F (or G), connect terminal G (or F) to ground,
and then verify that the front air mix actuator operates as shown in the table.
• If the operation condition is not normal, replace the front air mix actuator.
Terminal Front air mix actuator
F G operation
F
B+ Ground COLD → HOT
Ground B+ HOT → COLD G F E D C B A

G
MAX COLD MAX HOT
A
E
C

ac9uuw00001113

MAX HOT
60°

14°—21°
07-40
MAX COLD

ac9uuw00002301

2. Verify that the resistance between terminals A

BETWEEN A AND E BETWEEN E AND C
and E, and E and C matches the front air mix KILOHM
TERMINALS WIRE TERMINALS WIRE
actuator operation as shown in the graph. 4.8
• If the operation condition and resistance are
RESISTANCE

not normal, replace the front air mix actuator.

End Of Sie
WM: REAR AIR MIX ACTUATOR

1.2

MAX MAX MAX MAX

HOT COLD HOT COLD
FRONT AIR MIX ACTUATOR POSITION
ac9uuw00002425

REAR AIR MIX ACTUATOR REMOVAL/INSTALLATION

id074000806000
1. Slide the passenger-side front seat to the maximum forward end.
2. Disconnect the negative battery cable.
3. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(6) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)

07-40–7
1890-1U-06H(07-40).fm 8 ページ ２００６年１２月２０日　水曜日　午前１０時２９分

CONTROL SYSTEM
4. Remove in the order indicated in the table.
1 Rear air mix actuator connector
2 Screw
3 Rear air mix actuator 3

5. Install in the reverse order of removal.

End Of Sie 2

2 1
ac9uuw00001021

REAR AIR MIX ACTUATOR INSPECTION

id074000805900
1. Connect battery positive voltage to rear air mix actuator terminal F (or G), connect terminal G (or F) to ground,
and then verify that the rear air mix actuator operates as shown in the table.
• If the operation condition is not normal, replace the rear air mix actuator.
Terminal
Rear air mix actuator operation
F G
F
B+ Ground HOT → COLD
Ground B+ COLD → HOT G F E D C B A

G
MAX HOT MAX COLD
C
E
A

ac9uuw00001109

MAX HOT

80°

10° MAX COLD

ac9uuw00002294

2. Verify that the resistance between the terminals

BETWEEN C AND E BETWEEN E AND A
terminals C and E, and E and A matches the rear KILOHM
TERMINALS WIRE TERMINALS WIRE
air mix actuator operation as shown in the graph. 4.8
• If the operation condition and resistance are
RESISTANCE

not normal, replace the rear air mix actuator.

End Of Sie
WM: FRONT AIRFLOW MODE ACTUATOR

1.2

MAX MAX MAX MAX

COLD HOT COLD HOT
REAR AIR MIX ACTUATOR POSITION
am8rrw00000834

07-40–8
1890-1U-06H(07-40).fm 9 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
FRONT AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION
id074000804600
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(6) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(10)Front scuff plate inner (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(11)Front side trim (See 09-17-23 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(12)Glove compartment (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
(13)Hood release lever (See 09-14-46 HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)
(14)Lower panel (See 09-17-11 LOWER PANEL REMOVAL/INSTALLATION.)
(15)Lower column cover (See 09-17-8 COLUMN COVER REMOVAL/INSTALLATION.)
(16)Driver-side air bag module (See 08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
(17)Steering wheel (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(18)Combination switch (See 09-18-16 COMBINATION SWITCH REMOVAL/INSTALLATION.)
(19)Center panel (See 09-17-10 CENTER PANEL REMOVAL/INSTALLATION.)
(20)Meter hood (See 09-17-11 METER HOOD REMOVAL/INSTALLATION.) 07-40
(21)Instrument cluster (See 09-22-3 INSTRUMENT CLUSTER REMOVAL/INSTALLATION.)
(22)Audio unit (See 09-20-7 AUDIO UNIT REMOVAL/INSTALLATION.)
(23)Steering shaft (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(24)A-pillar trim (See 09-17-19 A-PILLAR TRIM REMOVAL/INSTALLATION.)
(25)Side panel (See 09-17-13 SIDE PANEL REMOVAL/INSTALLATION.)
3. Disconnect the front door wiring harness connector (Driver side). (See09-11-5 FRONT DOOR MODULE
REMOVAL/INSTALLATION.)
4. Disconnect the dashboard harness connectors.
5. Remove the brake switch from the brake pedal with the brake switch connector connected. (See 04-11-4
BRAKE PEDAL REMOVAL/INSTALLATION.)
6. Remove the selector lever component. (See 05-18-8 SELECTOR LEVER COMPONENT REMOVAL/
INSTALLATION.)
7. Remove the windshield wiper arm and blade. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE
REMOVAL/INSTALLATION.)
8. Remove the cowl grille. (See 09-16-13 COWL GRILLE REMOVAL/INSTALLATION.)
9. Remove the windshield wiper motor. (See 09-19-4 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)
10. Remove the dashboard. (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
11. Remove in the order indicated in the table.
1 Front airflow mode actuator connector
2 Screw
3
3 Front airflow mode actuator

12. Install in the reverse order of removal.

End Of Sie
2

1
ac9uuw00001152

07-40–9
1890-1U-06H(07-40).fm 10 ページ ２００６年１２月２０日　水曜日　午前１０時２９分

CONTROL SYSTEM
FRONT AIRFLOW MODE ACTUATOR INSPECTION
id074000804500
1. Connect battery positive voltage to front airflow mode actuator terminal F (or G), connect terminal G (or F) to
ground, and then verify that the front airflow mode actuator operates as shown in the table.
• If the operation condition is not normal, replace the front airflow mode actuator.
Terminal Front airflow mode
F G actuator operation
F
B+ Ground VENT → DEFROSTER
G F E D C B A
Ground B+ DEFROSTER → VENT
G
DEFROSTER VENT
C
E
A

ac9uuw00001114

VENT

A
B
BI-LEVEL
C
D
A:-4°—4°
E B:15°—23°
HEAT C:40°—48°
D:59°—67°
HEAT/DEF DEFROSTER E:86°—94°
am8rrw00000825

2. Verify that the resistance between terminals C

BETWEEN C AND E BETWEEN E AND A
and E, and E and A matches the front airflow KILOHM
TERMINALS WIRE TERMINALS WIRE
mode actuator operation as shown in the graph.
4.8
• If the operation condition and resistance are
RESISTANCE

not normal, replace the front airflow mode

actuator.
End Of Sie
1.2
WM: REAR AIRFLOW MODE ACTUATOR

VENT DEFROSTER VENT DEFROSTER

FRONT AIRFLOW MODE ACTUATOR POSITION
am8rrw00000826

REAR AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION

id074000804800
1. Slide the passenger-side front seat to the maximum forward end.
2. Disconnect the negative battery cable.
3. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(6) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)

07-40–10
1890-1U-06H(07-40).fm 11 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
4. Remove in the order indicated in the table.
1 Rear airflow mode actuator connector
1 3
2 Screw
3 Rear airflow mode actuator

5. Install in the reverse order of removal.

End Of Sie

2
ac9uuw00001023

REAR AIRFLOW MODE ACTUATOR INSPECTION

id074000804700
1. Connect battery positive voltage to rear airflow mode actuator terminal F (or G), connect terminal G (or F) to
ground, and then verify that the rear airflow mode actuator operates as shown in the table.
• If the operation condition is not normal, replace the rear airflow mode actuator.
Terminal Rear airflow mode
F G actuator operation
F
B+ Ground VENT → HEAT
Ground B+ HEAT → VENT M G F E D C B A

G 07-40
VENT HEAT
A
E
C

ac9uuw00001116

VENT

75°
2°—9°
HEAT
ac9uuw00001024

2. Verify that the resistance between terminals A

and E, and E and C matches the rear airflow BETWEEN A AND E BETWEEN E AND C
KILOHM
TERMINALS WIRE TERMINALS WIRE
mode actuator operation as shown in the graph. 4.8
• If the operation condition and resistance are
RESISTANCE

not normal, replace the rear airflow mode

actuator.
End Of Sie
WM: FRONT BLOWER MOTOR
1.2

VENT HEAT VENT HEAT

REAR AIRFLOW MODE ACTUATOR POSITION

am8rrw00000829

07-40–11
1890-1U-06H(07-40).fm 12 ページ ２００６年１２月２０日　水曜日　午前１０時２８分

CONTROL SYSTEM
FRONT BLOWER MOTOR REMOVAL/INSTALLATION
id074000805000
1. Disconnect the negative battery cable.
2. Remove the dashboard under cover. (passenger side) (See 09-17-14 DASHBOARD UNDER COVER
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
1 Front blower motor connector
2 Screw
3 Front blower motor
3
4. Install in the reverse order of removal.
End Of Sie

2 1
ac9uuw00001025

FRONT BLOWER MOTOR INSPECTION

id074000804900
1. Connect battery positive voltage to front blower motor terminal B, connect terminal A to ground, and then verify
its operation.
• If there is any malfunction, replace the front blower motor.
End Of Sie
WM: REAR BLOWER MOTOR

B A

ampjjw00002520

REAR BLOWER MOTOR REMOVAL/INSTALLATION

id074000805400
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(6) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
(10)Selector lever component (See 05-18-8 SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
1 Rear blower motor connector
2 Screw
3 Rear blower motor
3
4. Install in the reverse order of removal.
End Of Sie
2

1
ac9uuw00001026

07-40–12
1890-1U-06H(07-40).fm 13 ページ ２００６年１２月２０日　水曜日　午前１０時２８分

CONTROL SYSTEM
REAR BLOWER MOTOR INSPECTION
id074000805300
1. Connect battery positive voltage to rear blower motor terminal B, connect terminal A to ground, and then verify
its operation.
• If there is any malfunction, replace the rear blower motor.
End Of Sie
WM: FRONT POWER MOS FET

B A

ampjjw00002522

FRONT POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET)
REMOVAL/INSTALLATION
id074000803800
1. Disconnect the negative battery cable.
2. Remove the dashboard under cover. (passenger side) (See 09-17-14 DASHBOARD UNDER COVER
REMOVAL/INSTALLATION.)
3. Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.) 07-40
4. Insert a flathead screwdriver as shown in the
figure and detach the fuse block tab by prying it in
the direction of the arrow. TAB
B
5. Press the fuse block and remove it from the
bracket.
6. Set the fuse block out of the way.

TAB

FUSE BLOCK
ac9uuw00001120

7. Remove in the order indicated in the table.

1
1 Front power MOS FET connector
2 Screw 2
2
3 Front power MOS FET

8. Install in the reverse order of removal.

End Of Sie
3

ac9uuw00000662

07-40–13
1890-1U-06H(07-40).fm 14 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
FRONT POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET)
INSPECTION
id074000803700
1. Verify that the continuity between the front power MOS FET terminals is as indicated in the table.
• If there is any malfunction, replace the front power MOS FET.
• If the blower motor operation is not normal even though no malfunction can be verified, inspect the front
climate control unit.
Tester lead
Resistance (kilohm)
+ -
2.2 KILOHMS
A B 2.2 B A
E A
A E Continuity detected F D B
A F Continuity detected
F
B A 2.2 1 KILOHM
B E Continuity detected
B F Continuity detected E
10 KILOHMS
E A ∞
E B ∞
am8rrw00000820
E F 11
F A ∞
F B ∞
F E 11

End Of Sie
REAR POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET)
WM: REAR POWER MOS FET

REMOVAL/INSTALLATION
id074000804000
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(6) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
3
1 Rear power MOS FET connector
2 Screw 1
3 Rear power MOS FET 2

4. Install in the reverse order of removal.

End Of Sie

ac9uuw00001027

07-40–14
1890-1U-06H(07-40).fm 15 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
REAR POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET)
INSPECTION
id074000803900
1. Verify that the continuity between the rear power MOS FET terminals is as indicated in the table.
• If there is any malfunction, replace the rear power MOS FET.
• If the blower motor operation is not normal even though no malfunction can be verified, inspect the front
climate control unit.
Tester lead
Resistance (kilohm)
+ - 1.5 KILOHMS
A B ∞ D B C A
A C 11 D B
A D ∞
C
B A Continuity detected 1 KILOHM
B C Continuity detected
B D 1.5 A
10 KILOHMS
C A 11
C B ∞
am8rrw00000821
C D ∞
D A Continuity detected
D B 1.5
D C Continuity detected
07-40
End Of Sie
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY
WM: MAGNETIC CLUTCH

id074000800400
1. Install the SST (49 L061 001) or a commercially available filter wrench as shown in the figure and remove the
bolt.
When Using SST

49 L061 001

ac9uuw00001028

When Using Filter Wrench

2. Insert an appropriate bolt into the pressure plate
thread hole and tighten it until the pressure plate
is removed.
FILTER
WRENCH

ac9uuw00001029

07-40–15
1890-1U-06H(07-40).fm 16 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
3. Disassemble in the order indicated in the table.
4 R
1 Bolt 2
2 Pressure plate
3 Shim
4 Snap ring 7
5 A/C compressor pulley 6 R
6 Snap ring 5
3
(See 07-40-16 Snap Ring Installation Note.) 1 8
7 Stator 18 N·m
{1.8 kgf·m,
8 A/C compressor body 13 ft·lbf}

4. Assemble in the reverse order of disassembly.

5. Adjust the magnetic clutch clearance. (See 07-40-
16 MAGNETIC CLUTCH ADJUSTMENT.)

ac9uuw00001030

Snap Ring Installation Note

1. Install the snap ring so that the tapered area is on
the pressure plate side. SNAP RING STATOR
End Of Sie

A/C COMPRESSOR

TAPPER PRESSURE
PLATE SIDE

ac9uuw00001039

MAGNETIC CLUTCH ADJUSTMENT

id074000800500
1. Secure the A/C compressor to the vise.
2. Secure the magnet base to the vise and install the PRESSURE
dial gauge to the position shown in the figure. PLATE
3. Set the dial gauge to 0.
4. Connect battery voltage to stator terminal A and A/C
the A/C compressor body to ground to operate COMPRESSOR
the magnet clutch.
5. Verify that the dial gauge graduation is within the VISE
standard.
• If the clearance is not within the specification,
adjust the clearance by changing the type or DIAL GAUGE MAGNET BASE
number of shims.
ac9uuw00001031

Magnetic clutch clearance

0.35—0.65 mm {0.014—0.025 in}

End Of Sie

07-40–16
1890-1U-06H(07-40).fm 17 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
MAGNETIC CLUTCH INSPECTION
id074000800600
1. Connect battery positive voltage to magnetic
clutch terminal A, connect terminal B to ground.

ac9uuw00001032

2. Verify that the magnetic clutch operates.

• If there is any malfunction, replace the
magnetic clutch.
A
End Of Sie
WM: SOLAR RADIATION SENSOR

B A

B
07-40

ac9uuw00002468

SOLAR RADIATION SENSOR REMOVAL/INSTALLATION

id074000802800
1. Disconnect the negative battery cable.
2. Remove the cover from the dashboard using a flathead screwdriver wrapped with protective tape.
3. Detach the solar radiation sensor connector tab in the position shown in the figure and disconnect the solar
radiation sensor connector.
4. Press the solar radiation sensor tab and remove
SOLAR
the solar radiation sensor from the cover. RADIATION FRONT
5. Install in the reverse order of removal. SENSOR
COVER
End Of Sie TAB TAB

TAB

CONNECTOR

ac9uuw00001033

SOLAR RADIATION SENSOR INSPECTION

id074000802900
1. Using a tester, connect the positive (+) lead to solar radiation sensor terminal A, the negative (-) lead to
terminal B or C, then measure the resistance.
• If the resistance is not normal, replace the solar radiation sensor.

Resistance
except ∞ ohms

2. Block the light to the solar radiation sensor, connect the positive (+) lead of a tester to solar radiation sensor
terminal B or C and negative (-) lead to terminal A, then measure the resistance.
• If the resistance is not normal, replace the solar radiation sensor.

Resistance
∞ ohms (no continuity)

07-40–17
1890-1U-06H(07-40).fm 18 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
3. Shine an incandescent light directly on the solar
A
radiation sensor.
4. Using a tester, connect the positive (+) lead to
solar radiation sensor terminal B or C, the
negative (-) lead to terminal A, then measure the
resistance. C B
• If the resistance is not normal, replace the
solar radiation sensor. C B A

Resistance
except ∞ ohms
am8rrw00001841
End Of Sie
AMBIENT TEMPERATURE SENSOR REMOVAL/INSTALLATION
WM: AMBIENT TEMPERATURE SENSOR

id074000803200
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Remove in the order indicated in the table.
1 Ambient temperature sensor connector
1
2 Ambient temperature sensor

4. Install in the reverse order of removal.

End Of Sie
2

ac9uuw00001034

AMBIENT TEMPERATURE SENSOR INSPECTION

id074000803300
1. Measure the temperature around the ambient
KILOHM
temperature sensor and measure the resistance
16
between the ambient temperature sensor
terminal.
• If the characteristics of the ambient 14
temperature sensor are not as shown in the
graph, replace the ambient temperature 12
sensor.
End Of Sie
RESISTANCE

WM: CABIN TEMPERATURE SENSOR

10

0
-10 0 10 20 30 40 50
{14} {32} {50} {68} {86} {104} {122}
TEMPERATURE °C {°F}
am8rrw00000818

07-40–18
1890-1U-06H(07-40).fm 19 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
CABIN TEMPERATURE SENSOR REMOVAL/INSTALLATION
id074000807800
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Dashboard under cover (Driver side) (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
(2) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(3) Console panel (LH) (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(4) Hood release lever (See 09-14-46 HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)
(5) Lower panel (See 09-17-11 LOWER PANEL REMOVAL/INSTALLATION.)
3. Remove the screw.
4. Remove the cabin temperature sensor cover in
the direction of the arrow.
5. Remove the cabin temperature sensor. SCREW
CABIN
6. Install in the reverse order of removal. TEMPERRATURE
End Of Sie SENSOR

CABIN
TEMPERRATURE
SENSOR COVER
07-40

ac9uuw00002316

CABIN TEMPERATURE SENSOR INSPECTION

id074000807700
1. Measure the temperature around the cabin temperature sensor and measure the resistance between cabin
temperature sensor terminal.
• If the characteristics of the cabin temperature sensor are not as shown in the graph, replace the cabin
temperature sensor.
End Of Sie
WM: FRONT EVAPORATOR TEMPERATURE SENSOR KILOHM
18

16

14

12
RESISTANCE

10

0
-10 0 10 20 30 40 50
{14} {32} {50} {68} {86} {104} {122}

TEMPERATURE °C {°F}
am8rrw00000835

FRONT EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION

id074000804200
1. Remove the front evaporator temperature sensor from the front A/C unit. (See 07-11-6 FRONT A/C UNIT
DISASSEMBLY/ASSEMBLY.)
End Of Sie

07-40–19
1890-1U-06H(07-40).fm 20 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
FRONT EVAPORATOR TEMPERATURE SENSOR INSPECTION
id074000804100
1. Set the fan speed MAX HI.
2. Set the temperature control at MAX COLD.
3. Set the RECIRCULATE mode.
4. Turn the A/C switch off.
5. Close all doors and windows.
6. Wait for 5 min.
7. Remove the glove compartment (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
8. Disconnect the front evaporator temperature sensor connector.
9. Measure the temperature at the blower inlet.
10. Measure the resistance between the front
KILOHM
evaporator temperature sensor terminals.
• If the resistance is not as shown in the graph, 14
replace the front evaporator temperature
sensor. 12
End Of Sie
WM: REAR EVAPORATOR TEMPERATURE SENSOR

10

RESISTANCE 8

0
-10 0 10 20 30 40 50
{14} {32} {50} {68} {86} {104} {122}
TEMPERATURE °C {°F}
am8rrw00000822

07-40–20
1890-1U-06H(07-40).fm 21 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
REAR EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION
id074000804400
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(6) Dashboard under cover (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
(7) Console panel (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)
(8) Console cover (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
(9) Console (See 09-17-16 CONSOLE REMOVAL/INSTALLATION.)
3. Disconnect the rear evaporator temperature REAR EVAPORATOR
sensor connector and remove it from the rear A/C TEMPERATURE
unit. SENSOR
4. Insert a flathead screwdriver as shown in the CONNECTOR
figure and remove the clip by prying it off.
5. Remove the rear evaporator temperature sensor.
6. Install in the reverse order of removal.
End Of Sie

07-40
CLIP REAR EVAPORATOR
TEMPERATURE
SENSOR

CLIP
ac9uuw00001036

REAR EVAPORATOR TEMPERATURE SENSOR INSPECTION

id074000804300
1. Measure the temperature at the blower inlet.
2. Measure the resistance between the rear
KILOHM
evaporator temperature sensor terminals. 14
• If the resistance is not as shown in the graph,
replace the rear evaporator temperature
sensor. 12
End Of Sie
WM: REFRIGERANT PRESSURE SWITCH

10
RESISTANCE

0
-10 0 10 20 30 40 50
{14} {32} {50} {68} {86} {104} {122}
TEMPERATURE °C {°F}
am8rrw00000823

07-40–21
1890-1U-06H(07-40).fm 22 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION
id074000802600
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07-10-6 REFRIGERANT RECOVERY.) (See 07-10-3
REFRIGERANT CHARGING.)
3. Grasp the piping block using pliers and remove the pressure switch using a spanner.
4. Disconnect the refrigerant pressure switch connector.
5. Remove in the order indicated in the table.
1 Refrigerant pressure switch connector
2 Refrigerant pressure switch
(See 07-40-22 Refrigerant Pressure Switch 1
Installation Note.)
2
6. Install in the reverse order of removal.
7. Perform the refrigerant system performance test. R
(See 07-10-7 REFRIGERANT SYSTEM
PERFORMANCE TEST.)

ac9uuw00001037
Refrigerant Pressure Switch Installation Note
1. Apply compressor oil to O-ring and connect the joint.
End Of Sie
REFRIGERANT PRESSURE SWITCH INSPECTION
id074000802700
1. Install the manifold.
2. Disconnect the refrigerant pressure switch connector.
3. Verify the high-pressure side reading of the gauge HI AND LO PRESSURE
and continuity between the refrigerant pressure 2.94—3.17
0.198—0.22 {30.0—32.3,
switch terminals. {2.02—2.24, 28.8—31.9 427—459}
CONTINUITY

NO CONTINUITY

0.02 0.57—0.61
{0.20, 2.90} {5.82—6.22,
2
MPa {kgf/cm , psi} 82.7—88.4}
am8rrw00000837

• If there is any malfunction, replace the

MEDIUM-PRESSURE
refrigerant pressure switch. 1.11—1.35
{11.4—13.7, 161—195}
CONTINUITY

NO CONTINUITY
1.44—1.60
{14.7—16.3, 209—232}
MPa {kgf/cm2, psi}
am8rrw00000838

End Of Sie
WM: FRONT CLIMATE CONTROL UNIT

HI AND LO
B
PRESSURE D A
C B C

D A

MEDIUM PRESSURE

am8rrw00000839

07-40–22
1890-1U-06H(07-40).fm 23 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
FRONT CLIMATE CONTROL UNIT REMOVAL/INSTALLATION
id074000805200
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Center panel (See 09-17-10 CENTER PANEL REMOVAL/INSTALLATION.)
3. Remove the screws.
4. Remove the front climate control unit.
5. Install in the reverse order of removal.
End Of Sie
CENTER
PANEL

FRONT CLIMATE
CONTROL UNIT

SCREW

07-40
SCREW

ac9uuw00001154

FRONT CLIMATE CONTROL UNIT INSPECTION

id074000805100
1. Connect the front climate control unit connector.
2. Turn the ignition switch to the ON position.
3. Connect the negative (-) lead of the tester to body ground.
4. By inserting the positive (+) lead of the tester into each front climate control unit terminal, measure the voltage
according to the terminal voltage table.
• If there is any malfunction, inspect the parts under “Inspection item (s)”.
— If the parts under “Inspection item (s)” are found to be normal, replace the front climate control unit.

Terminal Voltage Table (Reference)

1W 1U 1S 1Q 1O 1M 1K 1I 1G 1E 1C 1A 2O 2M 2K 2I 2G 2E 2C 2A 3I 3G 3E 3C 3A
1X 1V 1T 1R 1P 1N 1L 1J 1H 1F 1D 1B 2P 2N 2L 2J 2H 2F 2D 2B 3J 3H 3F 3D 3B

ac9uuw00001117

Term Signal Measurement

Connected to Voltage (V) Inspection item (s)
inal name condition
Temperature control • Wiring harness: continuity, short circuit
dial (driver side): 1.0 or less (Front climate control unit—driver-side
Motor Driver-side front air Moving towards COLD front air mix actuator: 1A—G, 1F—F)
1A • Driver-side front air mix actuator
operation mix actuator Temperature control
dial (driver side): B+
Moving towards HOT
• Wiring harness: continuity, short circuit
(Front climate control unit— BCM: 1B—
1B B+ BCM Under any condition B+
5H)
• BCM

07-40–23
1890-1U-06H(07-40).fm 24 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
Temperature control • Wiring harness: continuity, short circuit
dial (passenger side): B+ (Front climate control unit—passenger-
Passenger-side Moving towards COLD side front air mix actuator: 1C—G, 1E—
Motor
1C front air mix F)
operation Temperature control
actuator • Passenger-side front air mix actuator
dial (passenger side): 1.0 or less
Moving towards HOT
Seat warmer switch off B+ • Wiring harness: continuity, short circuit
Seat warmer (Front climate control unit— seat
1D Seat warmer relay
(LH) on/off Seat warmer switch on 1.0 or less warmer (LH) relay (relay block): 1D—A)
• Seat warmer (LH) relay
Temperature control • Wiring harness: continuity, short circuit
dial (passenger side): 1.0 or less (Front climate control unit—passenger-
Passenger-side Moving towards COLD side front air mix actuator: 1C—G, 1E—
Motor
1E front air mix F)
operation Temperature control
actuator • Passenger-side front air mix actuator
dial (passenger side): B+
Moving towards HOT
Temperature control • Wiring harness: continuity, short circuit
dial (driver side): B+ (Front climate control unit—driver-side
Motor Driver-side front air Moving towards COLD front air mix actuator: 1A—G, 1F—F)
1F • Driver-side front air mix actuator
operation mix actuator Temperature control
dial (driver-side): 1.0 or less
Moving towards HOT
Temperature control • Wiring harness: continuity, short circuit
dial (rear side): Moving B+ (Front climate control unit—Rear air mix
Motor Rear air mix towards COLD actuator: 1G—F, 1I—G)
1G • Rear air mix actuator
operation actuator Temperature control
dial (rear side): Moving 1.0 or less
towards HOT
Defroster switch on 1.0 or less • Wiring harness: continuity, short circuit
Motor Front airflow mode (Front climate control unit—front airflow
1H Mode switch: Moving
operation actuator B+ mode actuator: 1H—G, 1J—F)
towards VENT • Front airflow mode actuator
Temperature control • Wiring harness: continuity, short circuit
dial (rear side): Moving 1.0 or less (Front climate control unit—Rear air mix
Motor Rear air mix towards COLD actuator: 1G—F, 1I—G)
1I • Rear air mix actuator
operation actuator Temperature control
dial (rear side): Moving B+
towards HOT
Defroster switch on B+ • Wiring harness: continuity, short circuit
Motor Front airflow mode (Front climate control unit—front airflow
1J Mode switch: Moving
operation actuator 1.0 or less mode actuator: 1H—G, 1J—F)
towards VENT • Front airflow mode actuator
Seat warmer switch off B+ • Wiring harness: continuity, short circuit
(Front climate control unit— seat
Seat warmer
1K Seat warmer relay warmer (RH) relay (main fuse block):
(RH) on/off Seat warmer switch on 1.0 or less 1K—A)
• Seat warmer (RH) relay
Temperature control • Wiring harness: continuity, short circuit
dial (rear side): Moving B+ (Front climate control unit—Rear airflow
Motor Rear airflow mode towards HOT mode actuator: 1L—G, 1N—F)
1L • Rear airflow mode actuator
operation actuator Temperature control
dial (rear side): Moving 1.0 or less
towards COLD
REC switch: Switched • Wiring harness: continuity, short circuit
B+
Motor to RECIRCULATE (Front climate control unit—air intake
1M Air intake actuator actuator: 1M—A, 1O—C)
operation REC switch: Switched
to FRESH
1.0 or less • Air intake actuator
Temperature control • Wiring harness: continuity, short circuit
dial (rear side): Moving 1.0 or less (Front climate control unit—Rear airflow
Motor Rear airflow mode towards HOT mode actuator: 1L—G, 1N—F)
1N • Rear airflow mode actuator
operation actuator Temperature control
dial (rear side): Moving B+
towards COLD

07-40–24
1890-1U-06H(07-40).fm 25 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
REC switch: Switched • Wiring harness: continuity, short circuit
1.0 or less
Motor to RECIRCULATE (Front climate control unit—air intake
1O Air intake actuator actuator: 1M—A, 1O—C)
operation REC switch: Switched
to FRESH
B+ • Air intake actuator
Off Approx. 7.3 1. Wiring harness: continuity, short circuit
1st. Approx. 5.4 (Front climate control unit—front power
MOS FET: 1P—C, 1R—A)
2nd. Approx. 4.6 2. Wiring harness: continuity (Front power
Front blower Airflow 3rd. Approx. 3.7
Front power MOS MOS FET—body ground: D—ground)
1P motor volume
FET 3. Front power MOS FET
feedback control dial 4th. Approx. 2.9
5th. Approx. 2.0 4. Front blower motor
5. Front blower relay
6th. Approx. 1.1 6. HEATER 50 A fuse
7th. 1.0 or less
• Wiring harness: continuity, short circuit
(Front climate control unit—rear window
Rear Rear window defroster
1.0 or less defroster relay (main fuse block): 1Q—
window Rear window switch on
1Q A)
defroster defroster relay • Rear window defroster relay
switch
Rear window defroster • Front climate control unit: terminal
B+
switch off voltage (1W, 1X)
Off 1.0 or less • Front climate control unit: terminal 07-40
1st. Approx. 2.1 voltage (1P)
2nd. Approx. 2.2
Front blower Airflow 3rd. Approx. 2.3
Front power MOS
1R fan speed volume
FET
control control dial 4th. Approx. 2.4
5th. Approx. 2.5
6th. Approx. 2.7
7th. Approx. 10.7
Fan switch on, A/C • Front climate control unit: terminal
1.0 or less
switch on voltage (1W, 1X)
• Wiring harness: continuity, short circuit
Refrigerant (Front climate control unit—refrigerant
1S A/C
pressure switch pressure switch: 1S—B) (Refrigerant
Fan switch off B+
pressure switch—PCM: C—1B)
• Refrigerant pressure switch
• PCM: terminal voltage (1B)
Off Approx. 8.5 1. Wiring harness: continuity, short circuit
1st. Approx. 6.1 (Front climate control unit—rear power
MOS FET: 1T—D, 1V—C)
Rear 2nd. Approx. 4.8
Rear blower 2. Wiring harness: continuity (Rear power
Rear power MOS airflow 3rd. Approx. 3.6
1T motor MOS FET—body ground: A—ground)
FET volume
feedback 3. Rear power MOS FET
control dial 4th. Approx. 1.9
4. Rear blower motor
5th. 1.0 or less 5. Rear blower relay
6. R.HEATER 40 A fuse
• Wiring harness: continuity (Front
Check connector is
1.0 or less climate control unit—check connector:
shorted.
1U—A)
On-board
1U diagnostic Check connector • Wiring harness: short circuit (Front
signal climate control unit—check connector:
Other B+ 1U—A)
• Front climate control unit: terminal
voltage (1W, 1X)
Off 1.0 or less • Front climate control unit: terminal
1st. Approx. 2.1 voltage (1T)
Rear
Rear blower 2nd. Approx. 2.2
Rear power MOS airflow
1V fan speed
FET volume 3rd. Approx. 2.2
control
control dial 4th. Approx. 2.3
5th. Approx. 2.4

07-40–25
1890-1U-06H(07-40).fm 26 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
Ignition switch is at ON • Wiring harness: continuity, short circuit
B+
position (Front climate control unit— fuse: 1W—
1W IG2 A/C 7.5 A fuse A/C 7.5 A)
Ignition switch is at
LOCK position
1.0 or less • A/C 7.5 A fuse
Under any condition: • Wiring harness: continuity (Front
1X Ground Body ground Inspect for continuity to 1.0 or less climate control unit—ground: 1X—
ground ground)
Because this terminal is for
ECT sensor communication, good/no good
2A Instrument cluster —
signal judgment by terminal voltage is not
possible.
• Driver-side front • Wiring harness: short circuit (Front
air mix actuator climate control unit—driver-side front air
• Passenger-side mix actuator, passenger-side front air
front air mix mix actuator, front airflow mode
actuator actuator, solar radiation sensor, rear air
• Front airflow mix actuator, rear airflow mode
2B +5 V mode actuator Under any condition 5.0 actuator: 2B—A, A, A, C, A, A)
• Solar radiation • Driver-side front air mix actuator
sensor • Passenger-side front air mix actuator
• Rear air mix • Front airflow mode actuator
actuator • Solar radiation sensor
• Rear airflow • Rear air mix actuator
mode actuator • Rear airflow mode actuator
Because this terminal is for
Information
communication, good/no good
2C display Information display —
judgment by terminal voltage is not
signal
possible.
Temperature control • Wiring harness: continuity, short circuit
dial (rear side): Moving Approx. 0.5 (Front climate control unit—rear airflow
towards COLD mode actuator: 2D—E)
Temperature control • Rear airflow mode actuator
Potentiomet Rear airflow mode dial (rear side): Moving • Front climate control unit: terminal
2D Approx. 2.4 voltage (2B)
er input actuator towards medium
temperature
Temperature control
dial (rear side): Moving Approx. 4.3
towards HOT
Mode switch: Moving • Wiring harness: continuity, short circuit
Approx. 1.0
towards VENT (Front climate control unit—front airflow
Mode switch: Moving mode actuator: 2E—E)
towards BI-LEVEL
Approx. 1.9 • Front airflow mode actuator
Potentiomet Front airflow mode • Front climate control unit: terminal
2E Mode switch: Moving voltage (2B)
er input actuator Approx. 2.5
towards HEAT
Mode switch: Moving
Approx. 3.3
towards HEAT/DEF
Defroster switch on Approx. 4.0
Temperature control • Wiring harness: continuity, short circuit
dial (driver side): Set (Front climate control unit—driver-side
4.0
temperature at MAX front air mix actuator: 2F—E)
Potentiomet Driver-side front air COLD • Driver-side front air mix actuator
2F • Front climate control unit: terminal
er input mix actuator Temperature control
dial (driver side): Set voltage (2B)
1.0
temperature at MAX
HOT
Temperature control • Wiring harness: continuity, short circuit
dial (passenger side): (Front climate control unit—passenger-
1.0
Set temperature at side front air mix actuator: 2G—E)
Passenger-side MAX COLD • Passenger-side front air mix actuator
Potentiomet
2G front air mix • Front climate control unit: terminal
er input Temperature control
actuator voltage (2B)
dial (passenger side):
4.0
Set temperature at
MAX HOT

07-40–26
1890-1U-06H(07-40).fm 27 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
• Wiring harness: continuity (Front
climate control unit—front evaporator
Front Compared with
temperature sensor: 2H—B, 2P—A)
evaporator Front evaporator temperature detected Refer to
2H • Wiring harness: short circuit (Front
temperature temperature sensor by front evaporator graph 1
climate control unit—front evaporator
sensor input temperature sensor
temperature sensor: 2H—B)
• Front evaporator temperature sensor
• Wiring harness: continuity (Front
climate control unit—ambient
Compared with
Ambient temperature sensor: 2I—B, 2P—A)
Ambient temperature detected Refer to
2I temperature • Wiring harness: short circuit (Front
temperature sensor by ambient graph 2
sensor input climate control unit—ambient
temperature sensor
temperature sensor: 2I—B)
• Ambient temperature sensor
• Wiring harness: continuity (Front
climate control unit—rear evaporator
Rear Compared with
temperature sensor: 2J—B, 2P—A)
evaporator Rear evaporator temperature detected Refer to
2J • Wiring harness: short circuit (Front
temperature temperature sensor by rear evaporator graph 3
climate control unit—rear evaporator
sensor input temperature sensor
temperature sensor: 2J—B)
• Rear evaporator temperature sensor
• Wiring harness: continuity (Front
climate control unit—cabin temperature 07-40
Compared with
Cabin sensor: 2K—B, 2P—A)
Cabin temperature temperature detected Refer to
2K temperature • Wiring harness: short circuit (Front
sensor by cabin temperature graph 4
sensor input climate control unit—cabin temperature
sensor
sensor: 2K—B)
• Cabin temperature sensor
2L — — — — —
Incandescent light • Wiring harness: continuity (Front
(approx. 60 W) shined climate control unit—solar radiation
Solar directly on the solar sensor: 2M—C, 2B—A)
4.0
radiation Solar radiation radiation sensor from a • Front climate control unit: terminal
2M distance of approx. voltage (2B)
sensor (LH) sensor
input 100 mm {3.9 in} • Solar radiation sensor
Blocking light to solar
1.0 or less
radiation sensor
Temperature control • Wiring harness: continuity, short circuit
dial (rear side): Set (Front climate control unit—rear air mix
1.3
temperature at MAX actuator: 2N—E)
Potentiomet Rear air mix COLD • Rear air mix actuator
2N • Front climate control unit: terminal
er input actuator Temperature control
dial (rear side): Set voltage (2B)
4.0
temperature at MAX
HOT
Incandescent light • Wiring harness: continuity (Front
(approx. 60 W) shined climate control unit—solar radiation
Solar directly on the solar sensor: 2O—B, 2B—A)
4.0
radiation Solar radiation radiation sensor from a • Front climate control unit: terminal
2O distance of approx. voltage (2B)
sensor (RH) sensor
input 100 mm {3.9 in} • Solar radiation sensor
Blocking light to solar
1.0 or less
radiation sensor

07-40–27
1890-1U-06H(07-40).fm 28 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
• Driver-side front • Front climate control unit: terminal
air mix actuator voltage (1X)
• Passenger-side
front air mix
actuator
• Front airflow
mode actuator
• Ambient
temperature
sensor
• Cabin
Under any condition:
Sensor temperature
2P Inspect for continuity to 1.0 or less
ground sensor
ground
• Front
evaporator
temperature
sensor
• Rear air mix
actuator
• Rear airflow
mode actuator
• Rear evaporator
temperature
sensor
3A — — — — —
3B — — — — —
• Wiring harness: continuity (Front
Rear control switch on B+ climate control unit—rear climate
control unit: 3C—F)
Rear climate
3C control unit
Rear climate • Wiring harness: short circuit (Front
control unit climate control unit—rear climate
display
Rear control switch off 1.0 or less control unit: 3C—F)
• Front climate control unit: terminal
voltage (1W, 1X)
• Wiring harness: short circuit (Front
climate control unit—TNS relay (main
Turn the headlight
fuse block): 3D—D)
switch to the off 1.0 or less
• ILLUMI 10 A fuse
position
• TNS relay
• Headlight switch
3D TNS signal TNS relay
• Wiring harness: continuity, short circuit
(Front climate control unit—TNS relay
Turn the headlight
(main fuse block): 3D—D)
switch to the TNS B+
• ILLUMI 10 A fuse
position
• TNS relay
• Headlight switch
Off 1.0 or less • Front climate control unit: terminal
1st. Approx. 1.3 voltage (1T)
Rear fan Airflow
Rear climate • Wiring harness: continuity, short circuit
3E control volume
control unit (Front climate control unit—rear climate
volume control dial Max HI Approx. 4.0 control unit: 3E—A)
• Rear climate control unit
Turn the headlight • Wiring harness: continuity, short circuit
switch to the off 1.0 or less (Front climate control unit—rear climate
Rear climate position control unit: 3F—H)
3F TNS signal • TNS relay
control unit Turn the headlight
switch to the TNS B+ • Headlight switch
position

07-40–28
1890-1U-06H(07-40).fm 29 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
Temperature control • Wiring harness: continuity, short circuit
dial (rear side): Moving 1.0 or less (Front climate control unit—rear airflow
towards COLD mode actuator: 3G—C)
Rear Temperature control • Rear climate control unit
temperature Rear climate dial (rear side): Moving • Front climate control unit: terminal
3G Approx. 2.5 voltage (2B)
control control unit towards medium
volume temperature
Temperature control
dial (rear side): Moving Approx. 4.2
towards HOT
• Wiring harness: continuity (Front
Rear climate
3H +5 V Under any condition 5.0 climate control unit—ground: 3H—
control unit
ground)
Under any condition: • Wiring harness: continuity (Front
Rear climate
3I Ground Inspect for continuity to 1.0 or less climate control unit—rear climate
control unit
ground control unit: 3I—E)
Turn the headlight • Wiring harness: continuity, short circuit
switch to the off 1.0 or less (Front climate control unit—instrument
Panel light position cluster: 3J—1I)
3J Instrument cluster • TNS relay
control input Turn the headlight
switch to the TNS B+ • Headlight switch
position 07-40

GRAPH 1 (FRONT EVAPORATOR TEMPERATURE SENSOR) GRAPH 2 (AMBIENT TEMPERATURE SENSOR)

(V) 5 (V) 5

4 4
VOLTAGE

VOLTAGE

3 3

2 2

1 1

0 0
-20 0 20 40 -20 0 20 40
{-4} {32} {68} {104} {-4} {32} {68} {104}
TEMPERATURE °C {°F} TEMPERATURE °C {°F}

GRAPH 3 (REAR EVAPORATOR TEMPERATURE SENSOR) GRAPH 4 (CABIN TEMPERATURE SENSOR)

(V) 5 (V) 5

4 4
VOLTAGE

VOLTAGE

3 3

2 2

1 1

0 0
-20 0 20 40 -20 0 20 40
{-4} {32} {68} {104} {-4} {32} {68} {104}
TEMPERATURE °C {°F} TEMPERATURE °C {°F}

End Of Sie
WM: REAR CLIMATE CONTROL UNIT

07-40–29
1890-1U-06H(07-40).fm 30 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
REAR CLIMATE CONTROL UNIT REMOVAL/INSTALLATION
id074000805600
1. Disconnect the negative battery cable.
2. Remove the console cover. (See 09-17-16 CONSOLE COVER REMOVAL/INSTALLATION.)
3. Remove the rear cooler duct. (See 07-11-13 REAR COOLER DUCT REMOVAL/INSTALLATION.)
4. Remove the screws. REAR CLIMATE CONTROL UNIT
5. Remove the rear climate control unit.
6. Install in the reverse order of removal.
End Of Sie

SCREW

ac9uuw00001038

REAR CLIMATE CONTROL UNIT INSPECTION

id074000805500
1. Connect the rear climate control unit connector.
2. Turn the ignition switch to the ON position.
3. Connect the negative (-) lead of the tester to body ground.
4. By inserting the positive (+) lead of the tester into each rear climate control unit terminal, measure the voltage
according to the terminal voltage table.
• If there is any malfunction, inspect the parts under “Inspection item (s)”.
— If the parts under “Inspection item (s)” are found to be normal, replace the rear climate control unit.

Terminal voltage table (Reference)

A C E G * *
* D F H * *

ac9uuw00001118

Terminal Signal name Connected to Measurement condition Voltage (V) Inspection item (s)
Off 1.0 or less • Front climate control unit:
1st. Approx. 1.3 terminal voltage (1T)
• Wiring harness:
Rear fan control Front climate Airflow volume continuity, short circuit
A
volume control unit control dial (Front climate control
Max HI Approx. 4.0 unit—rear climate control
unit: 3E—A)
• Rear climate control unit
B — — — — —
Temperature control dial: • Wiring harness:
1.0 or less
Moving towards COLD continuity, short circuit
Temperature control dial: (Front climate control
Rear
Front climate Moving towards medium Approx. 2.5 unit—rear airflow mode
C temperature
control unit temperature actuator: 3G—C)
control volume
• Rear climate control unit
Temperature control dial:
Approx. 4.2 • Front climate control unit:
Moving towards HOT terminal voltage (2B)
• Front climate control unit:
terminal voltage (3H)
Front climate • Wiring harness:
D +5 V Under any condition 5.0
control unit continuity (Front climate
control unit—rear climate
control unit: 3H—D)

07-40–30
1890-1U-06H(07-40).fm 31 ページ ２００６年１２月１９日　火曜日　午後１２時５９分

CONTROL SYSTEM
Terminal Signal name Connected to Measurement condition Voltage (V) Inspection item (s)
• Wiring harness:
Front climate Under any condition: Inspect for continuity (Front climate
E Ground 1.0 or less
control unit continuity to ground control unit—rear climate
control unit: 3I—E)
• Wiring harness:
continuity (Front climate
Rear control switch on B+
control unit—rear climate
control unit: 3C—F)
Rear climate
F control unit
Front climate • Wiring harness: short
control unit circuit (Front climate
display
control unit—rear climate
Rear control switch off 1.0 or less
control unit: 3C—F)
• Front climate control unit:
terminal voltage (1W, 1X)
Turn the headlight switch to the • Wiring harness:
1.0 or less
off position continuity, short circuit
(Rear climate control
Panel light Instrument
G unit—instrument cluster:
control input cluster Turn the headlight switch to the
B+ G—1I)
TNS position • TNS relay
• Headlight switch
Turn the headlight switch to the • Wiring harness:
1.0 or less
off position continuity, short circuit 07-40
(Front climate control
Front climate
H TNS signal unit—rear climate control
control unit Turn the headlight switch to the
B+ unit: 3F—H)
TNS position • TNS relay
• Headlight switch
I — — — — —
J — — — — —

End Of Sie

07-40–31
1890-1U-06H(07-50).fm 1 ページ ２００６年１２月１９日　火曜日　午後１時２分

TECHNICAL DATA
07-50 TECHNICAL DATA
HVAC TECHNICAL DATA . . . . . . . . . . . . 07-50–1

End of Toc
HVAC TECHNICAL DATA
WM: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)

id075000800100

Item Specification
REFRIGERANT SYSTEM
Type R-134a
Refrigerant
Regular amount (approx. quantity) (g {oz}) 660—710 {23.3—25.0}
BASIC SYSTEM
Type DENSO OIL8
A/C compressor Lubrication oil Sealed volume
(approx. (ml {cc, fl oz}) 160 {160, 5.41}
quantity)
CONTROL SYSTEM
A/C compressor Magnetic clutch clearance (mm {in}) 0.35—0.65 {0.014—0.025}

End Of Sie
07-50

07-50–1
1890-1U-06H(07-60).fm 1 ページ ２００６年１２月１９日　火曜日　午後１時３分

SERVICE TOOLS
07-60 SERVICE TOOLS
HVAC SST . . . . . . . . . . . . . . . . . . . . . . . . 07-60–1

End of Toc
HVAC SST
WM: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)

id076000800100

49 L061 001

Holder
— —

End Of Sie

07-60

07-60–1
1890-1U-06H(08-02).fm 1 ページ ２００６年１２月１９日　火曜日　午後１時５分

RESTRAINTS 08SECTION

Toc of SCT
ON-BOARD DIAGNOSTIC . . . . 08-02 AIR BAG SYSTEM . . . . . . . . . . 08-10
SYMPTOM SEAT BELT. . . . . . . . . . . . . . . . 08-11
TROUBLESHOOTING . . . . . . 08-03 SERVICE TOOLS . . . . . . . . . . . 08-60
Toc of SCT
08-02 ON-BOARD DIAGNOSTIC
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 08-02–1 DTC B1055, B1996, B1997, B1998,
Outline. . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–1 B1999. . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–32
FLOWCHART . . . . . . . . . . . . . . . . . . . . . . 08-02–2 DTC B1056, B2777, B2778, B2779,
AIR BAG SYSTEM WIRING DIAGRAM B2780. . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–35
(ON-BOARD DIAGNOSTIC). . . . . . . . . . 08-02–3 DTC B1057, B1916, B1932, B1934,
DTC DISPLAY. . . . . . . . . . . . . . . . . . . . . . 08-02–4 B1936. . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–37
CLEARING DTC . . . . . . . . . . . . . . . . . . . . 08-02–4 DTC B1058, B2228, B2230, B2232,
DTC TABLE . . . . . . . . . . . . . . . . . . . . . . . 08-02–4 B2234. . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–40
PID/DATA MONITOR DISPLAY . . . . . . . . 08-02–10 DTC B1059, B2229, B2231, B2233, 08-02
PID/DATA MONITOR TABLE . . . . . . . . . . 08-02–10 B2235. . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–42
DTC B1013 . . . . . . . . . . . . . . . . . . . . . . . . 08-02–12 DTC B105A . . . . . . . . . . . . . . . . . . . . . . . 08-02–45
DTC B1046, B2773, B2774, B2775, DTC B105B, B110C, B1144,
B2776 . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–13 B1145. . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–45
DTC B1047, B1992, B1993, B1994, DTC B105F, B110D, B1146,
B1995 . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–16 B1147. . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–48
DTC B1048, B1925, B1933, B1935, DTC B110E, B110F, B2856, B2886,
B1938 . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–18 B2887. . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–50
DTC B1049, B1881, B1882, B1883, DTC B1231 . . . . . . . . . . . . . . . . . . . . . . . 08-02–51
B1886 . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–21 DTC B1317, B1318 . . . . . . . . . . . . . . . . . 08-02–51
DTC B104B, B104E, B1051, DTC B1342, B1921 . . . . . . . . . . . . . . . . . 08-02–53
U2017 . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–23 DTC B1868 . . . . . . . . . . . . . . . . . . . . . . . 08-02–53
DTC B104C, B104F, B1050, Diagnostic Procedure . . . . . . . . . . . . . . 08-02–53
U2018 . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–26 DTC B1884, B1890 . . . . . . . . . . . . . . . . . 08-02–54
DTC B104D, B2226, B2227, DTC B2290 . . . . . . . . . . . . . . . . . . . . . . . 08-02–56
B2855 . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–28 DTC B2477 . . . . . . . . . . . . . . . . . . . . . . . 08-02–57
DTC B1054, B1877, B1878, B1879, DTC C1946, C1947, C1948, C1981,
B1885 . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–30 C1982. . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–58

End of Toc
FOREWORD
WM: AIR BAG SYSTEM

id080200800100
Outline
• The OBD (on-board diagnostic) system has the following functions:
— Malfunction detection function: Detects malfunctions in the air bag system and outputs DTCs.
— Data monitor function: Reads out specific input/output signals and the system status.
• Diagnostic DTCs can be read/cleared using the M-MDS.
End Of Sie

08-02–1
1890-1U-06H(08-02).fm 2 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
FLOWCHART
id080200800200
• Use the following flowchart to verify the cause of the trouble.

Note
• While performing the inspection of the past malfunction code, the applicable DTCs may be added to
memory by removing or disconnecting the related parts. Inspect only the DTCs that were indicated before
inspecting.
• When DTCs of the present malfunction are no longer output after present or past malfunctions or both
have been repaired, be sure to perform past malfunction display cancellation to prevent repair of
malfunctions that have already been repaired.

START

Turn ignition switch to ON position. Confirm malfunction symptom, then

Does air bag system warning light illuminate for No
troubleshoot warning light circuit of
approx. 6 s and then go off? applicable malfunction, referring to
TROUBLESHOOTING INDEX.
Yes

Present malfunction Yes

Present malfunction
Using M-MDS, verify if DTCs are present. Inspect DTCs one by one starting from
Is DTC displayed? the smallest code, referring to DTC
TABLE.

No

Using M-MDS, No
Past malfunction Yes
Using M-MDS, verify if a DTC has been verify if DTCs are present.
stored in SAS control module. Is DTC displayed?
Is DTC displayed?

Yes
No Yes

Shake related applicable wiring harnesses of applicable malfunctions.

Is DTC displayed?

Note
For DTCs that are the same as DTCs displayed in past malfunction diagnosis, go to Yes.
For DTCs that are not displayed but were displayed in past malfunction diagnosis, go to No.

No

Past malfunction
Inspect all DTCs starting from the smallest code.
However, if inspection item for part that has already been repaired appears during
inspection, finish inspection for that DTC at that point in time.

Using M-MDS, clear any stored DTCs in SAS control module.

Yes Using M-MDS, verify if a DTC has been stored in SAS control module.
Is DTC displayed?

No

END

acxuuw00001022
End Of Sie

08-02–2
1890-1U-06H(08-02).fm 3 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
AIR BAG SYSTEM WIRING DIAGRAM (ON-BOARD DIAGNOSTIC)
id080200808800

IG1
CLOCK SPRING

1D 1I 1C 3B INFLATOR
NO.1
1X 1M 1D 3A
DRIVER-SIDE
TO CAN SYSTEM-
RELATED UNIT AIR BAG
1T MODULE
1U 1A 4B
INFLATOR
NO.2
1Q 1B 4A

INSTRUMENT
CLUSTER

1J 1A INFLATOR
SEAT TRACK A 2AB NO.1
POSITION 1N 1E
SENSOR C 2AF PASSENGER-SIDE
IG1
AIR BAG MODULE
INFORMATION 1V 2A
1G INFLATOR
DISPLAY NO.2
1R 2B
TWISTED
IG1
SEAT PAIR
WEIGHT 1A
SENSOR 1B SEAT 3A
(LH) WEIGHT 2J A DRIVER-SIDE
SENSOR 3D PRE-TENSIONER
2AJ
SEAT
CONTROL
2N B SEAT BELT 08-02
WEIGHT 2A
MODULE 3B
SENSOR 2B
(RH) SAS 2AK A DRIVER-SIDE
CONTROL CURTAIN AIR BAG
A 1W MODULE
CRASH ZONE 2AG B MODULE
SENSOR B 1S
TWISTED PAIR
2F A
A 2W DRIVER-SIDE SIDE
DRIVER-SIDE
AIR BAG MODULE
BUCKLE SWITCH B 2B B

PASSENGER-SIDE A 2C
BUCKLE SWITCH B 2E A PASSENGER-SIDE
PRE-TENSIONER
A 2O 2A B SEAT BELT
DRIVER-SIDE SIDE AIR
BAG SENSOR No. 1 2S
B
2AL A PASSENGER-SIDE
A 2K CURTAIN AIR BAG
PASSENGER-SIDE SIDE
2AH B MODULE
AIR BAG SENSOR No. 1 2G
B

A 2AM 2I A
DRIVER-SIDE SIDE AIR PASSENGER-SIDE
BAG SENSOR No. 2 2AI SIDE AIR BAG
B 2M B

A 2AA
PASSENGER-SIDE SIDE
AIR BAG SENSOR No. 2 B 2AE
TWISTED PAIR
1K

2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1U 1Q 1M 1I 1E 1A

2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1V 1R 1N 1J 1F 1B
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1W 1S 1O 1K 1G 1C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1X 1T 1P 1L 1H 1D

ac9uuw00002217

08-02–3
1890-1U-06H(08-02).fm 4 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
End Of Sie

DTC DISPLAY
id080200800400
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
— Select the “Toolbox” tab.
— Select “Self Test”.
— Select “Modules”.
— Select “RCM”.
• When using the PDS (Pocket PC) DLC-2
— Select “Module Tests”.
— Select “RCM”.
— Select “Self Test”.
ac9uuw00000633
3. Verify the DTC according to the directions on the
screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
4. After completion of repairs, clear all DTCs stored in the SAS control module. (See 08-02-4 CLEARING DTC.)
End Of Sie
CLEARING DTC
id080200800500
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
— Select the “Toolbox” tab.
— Select “Self Test”.
— Select “Modules”.
— Select “RCM”.
• When using the PDS (Pocket PC) DLC-2
— Select “Module Tests”.
— Select “RCM”.
— Select “Self Test”.
ac9uuw00000633
3. Verify the DTC according to the directions on the
screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.
End Of Sie
DTC TABLE
id080200800600
• DTCs are common for present and past malfunction diagnosis.

Note
• When DTCs not shown in the DTC table are displayed, replace the SAS control module.
• If the air bag system warning light does not illuminate or remains illuminated when the ignition switch is
turned to the ON position, inspect and repair the air bag system warning light circuit, and then confirm that
the air bag system warning light is operational.
• The air bag system warning light flashes the DTC pattern for five cycles, and then remains illuminated
until the ignition switch is turned to the ACC or LOCK position.

DTC table
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
Seat weight sensor calibration (See 08-02-12
B1013 16 20
error DTC B1013.)
(See 08-02-13
Driver-side curtain air bag module
DTC B1046,
B1046 24 19 and other air bag module circuits
B2773, B2774,
short
B2775, B2776.)

08-02–4
1890-1U-06H(08-02).fm 5 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
(See 08-02-16
Driver-side side air bag module
DTC B1047,
B1047 22 17 and other air bag module circuits
B1992, B1993,
short
B1994, B1995.)
(See 08-02-18
Passenger-side air bag module
DTC B1048,
B1048 21 12 (inflator No.1) and other air bag
B1925, B1933,
module circuits short
B1935, B1938.)
(See 08-02-21
Passenger-side pre-tensioner
DTC B1049,
B1049 34 14 seat belt and other air bag module
B1881, B1882,
circuits short
B1883, B1886.)
(See 08-02-23
Driver-side side air bag sensor
DTC B104B,
B104B 43 8 No. 1 and other sensor circuits
B104E, B1051,
short to power supply
U2017.)
(See 08-02-26
Passenger-side side air bag
DTC B104C,
B104C 44 7 sensor No.1 and other sensor
B104F, B1050,
circuits short to power supply
U2018.)
(See 08-02-23
Crash zone sensor and other
DTC B104B, 08-02
B104D 42 11 sensor circuits short to power
B104E, B1051,
supply
U2017.)
(See 08-02-23
Driver-side side air bag sensor DTC B104B,
B104E 43 8
No.1 circuit open or short B104E, B1051,
U2017.)
Passenger-side side air bag
B104F sensor No.1 (internal circuit (See 08-02-26
abnormal) DTC B104C,
44 7
B104F, B1050,
Passenger-side side air bag U2018.)
B1050
sensor No.1 circuit open or short
(See 08-02-23
Driver-side side air bag sensor DTC B104B,
B1051 43 8
No.1 (internal circuit abnormal) B104E, B1051,
U2017.)
(See 08-02-30
Driver-side pre-tensioner seat belt
DTC B1054,
B1054 33 15 and other air bag module circuits
B1877, B1878,
short
B1879, B1885.)
(See 08-02-32
Passenger-side side air bag
DTC B1055,
B1055 23 16 module and other air bag module
B1996, B1997,
circuits short
B1998, B1999.)
(See 08-02-35
Passenger-side curtain air bag
DTC B1056,
B1056 25 18 module and other air bag module
B2777, B2778,
circuits short
B2779, B2780.)
(See 08-02-37
Driver-side air bag module
DTC B1057,
B1057 (inflator No.1) and other air bag
B1916, B1932,
module circuits short
B1934, B1936.)
19 13
(See 08-02-40
Driver-side air bag module
DTC B1058,
B1058 (inflator No.2) and other air bag
B2228, B2230,
module circuits short
B2232, B2234.)
(See 08-02-42
Passenger-side air bag module
DTC B1059,
B1059 21 12 (inflator No.2) and other air bag
B2229, B2231,
module circuits short
B2233, B2235.)

08-02–5
1890-1U-06H(08-02).fm 6 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
SAS control module activation
(See 08-02-45
B105A - Continuously illuminated 1 (deployment) control frequency
DTC B105A.)
error
(See 08-02-45
Driver-side side air bag sensor
DTC B105B,
B105B 46 10 No. 2 and other sensor circuits
B110C, B1144,
short to power supply
B1145.)
(See 08-02-48
Passenger-side side air bag
DTC B105F,
B105F 47 9 sensor No. 2 and other sensor
B110D, B1146,
circuits short to power supply
B1147.)
(See 08-02-45
Driver-side side air bag sensor DTC B105B,
B110C 46 10
No. 2 circuit open or short B110C, B1144,
B1145.)
(See 08-02-48
Passenger-side side air bag DTC B105F,
B110D 47 9
sensor No. 2 circuit open or short B110D, B1146,
B1147.)

Driver-side side air bag sensor

B110E 46 10
No.2 ID mismatch (See 08-02-50
DTC B110E,
B110F, B2856,
Passenger-side side air bag B2886, B2887.)
B110F 47 9
sensor No.2 ID mismatch

Driver-side side air bag sensor (See 08-02-45

B1144
No. 2 (internal circuit abnormal) DTC B105B,
46 10
Driver-side side air bag sensor B110C, B1144,
B1145 B1145.)
No. 2 (communication error)
Passenger-side side air bag
B1146 sensor No. 2 (internal circuit (See 08-02-48
abnormal) DTC B105F,
47 9
Passenger-side side air bag B110D, B1146,
B1147 sensor No. 2 (communication B1147.)
error)
SAS control module activation (See 08-02-51
B1231 13 3
(deployment) control freeze DTC B1231.)
SAS control module power supply
B1317 voltage increases (18.1 V or (See 08-02-51
- Continuously illuminated 1 more) DTC B1317,
SAS control module power supply B1318.)
B1318
voltage decreases (less than 8 V)

12 2 (See 08-02-53
SAS control module (internal
B1342 DTC B1342,
circuit abnormal)
B1921.)
- Continuously illuminated 1
Air bag system warning light (See 08-02-53
B1868 - - 1
malfunction DTC B1868.)
Driver-side pre-tensioner seat belt
B1877
circuit resistance high (See 08-02-30
Driver-side pre-tensioner seat belt DTC B1054,
B1878 33 15
circuit short to power supply B1877, B1878,
Driver-side pre-tensioner seat belt B1879, B1885.)
B1879
circuit short to body ground

08-02–6
1890-1U-06H(08-02).fm 7 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
Passenger-side pre-tensioner
B1881
seat belt circuit resistance high
Passenger-side pre-tensioner (See 08-02-21
B1882 seat belt circuit short to power DTC B1049,
34 14
supply B1881, B1882,
Passenger-side pre-tensioner B1883, B1886.)
B1883 seat belt circuit short to body
ground
Passenger air bag deactivation (See 08-02-54
B1884 18 21 (PAD) indicator circuit open or DTC B1884,
short to body ground B1890.)
(See 08-02-30
Driver-side pre-tensioner seat belt DTC B1054,
B1885 33 15
circuit resistance low B1877, B1878,
B1879, B1885.)
(See 08-02-21
Passenger-side pre-tensioner DTC B1049,
B1886 34 14
seat belt circuit resistance low B1881, B1882,
B1883, B1886.)
Passenger air bag deactivation (See 08-02-54
B1890 18 21 (PAD) indicator circuit short to DTC B1884,
power supply B1890.) 08-02
(See 08-02-37
Driver-side air bag module
DTC B1057,
B1916 19 13 (inflator No.1) circuit short to
B1916, B1932,
power supply
B1934, B1936.)
(See 08-02-53
Air bag diagnostic ground circuit
B1921 - Continuously illuminated 1 DTC B1342,
open
B1921.)
(See 08-02-18
Passenger-side air bag module
DTC B1048,
B1925 21 12 (inflator No.1) circuit short to
B1925, B1933,
power supply
B1935, B1938.)
(See 08-02-37
Driver-side air bag module
DTC B1057,
B1932 19 13 (inflator No.1) circuit resistance
B1916, B1932,
high
B1934, B1936.)
(See 08-02-18
Passenger-side air bag module
DTC B1048,
B1933 21 12 (inflator No.1) circuit resistance
B1925, B1933,
high
B1935, B1938.)
(See 08-02-37
Driver-side air bag module
DTC B1057,
B1934 19 13 (inflator No.1) circuit resistance
B1916, B1932,
low
B1934, B1936.)
(See 08-02-18
Passenger-side air bag module
DTC B1048,
B1935 21 12 (inflator No.1) circuit resistance
B1925, B1933,
low
B1935, B1938.)
(See 08-02-37
Driver-side air bag module
DTC B1057,
B1936 19 13 (inflator No.1) circuit short to body
B1916, B1932,
ground
B1934, B1936.)
(See 08-02-18
Passenger-side air bag module
DTC B1048,
B1938 21 12 (inflator No.1) circuit short to body
B1925, B1933,
ground
B1935, B1938.)

08-02–7
1890-1U-06H(08-02).fm 8 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
Driver-side side air bag module
B1992
circuit short to power supply
Driver-side side air bag module (See 08-02-16
B1993
circuit short to body ground DTC B1047,
22 17
Driver-side side air bag module B1992, B1993,
B1994 B1994, B1995.)
circuit resistance high
Driver-side side air bag module
B1995
circuit resistance low
Passenger-side side air bag
B1996 module circuit short to power
supply
Passenger-side side air bag (See 08-02-32
B1997 module circuit short to body DTC B1055,
23 16 ground B1996, B1997,
Passenger-side side air bag B1998, B1999.)
B1998
module circuit resistance high
Passenger-side side air bag
B1999
module circuit resistance low
Crash zone sensor (internal circuit (See 08-02-28
B2226
abnormal) DTC B104D,
42 11
Crash zone sensor B2226, B2227,
B2227 B2855.)
(communication error)
(See 08-02-40
Driver-side air bag module
DTC B1058,
B2228 19 13 (inflator No.2) circuit short to body
B2228, B2230,
ground
B2232, B2234.)
(See 08-02-42
Passenger-side air bag module
DTC B1059,
B2229 21 12 (inflator No.2) circuit short to body
B2229, B2231,
ground
B2233, B2235.)
(See 08-02-40
Driver-side air bag module
DTC B1058,
B2230 19 13 (inflator No.2) circuit short to
B2228, B2230,
power supply
B2232, B2234.)
(See 08-02-42
Passenger-side air bag module
DTC B1059,
B2231 21 12 (inflator No.2) circuit short to
B2229, B2231,
power supply
B2233, B2235.)
(See 08-02-40
Driver-side air bag module
DTC B1058,
B2232 19 13 (inflator No.2) circuit resistance
B2228, B2230,
high
B2232, B2234.)
(See 08-02-42
Passenger-side air bag module
DTC B1059,
B2233 21 12 (inflator No.2) circuit resistance
B2229, B2231,
high
B2233, B2235.)
(See 08-02-40
Driver-side air bag module
DTC B1058,
B2234 19 13 (inflator No.2) circuit resistance
B2228, B2230,
low
B2232, B2234.)
(See 08-02-42
Passenger-side air bag module
DTC B1059,
B2235 21 12 (inflator No.2) circuit resistance
B2229, B2231,
low
B2233, B2235.)
Seat weight sensor signal (See 08-02-56
B2290 16 20
malfunction DTC B2290.)

(See 08-02-57
B2477 54 6 Configuration error
DTC B2477.)

08-02–8
1890-1U-06H(08-02).fm 9 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
Driver-side curtain air bag module
B2773
circuit resistance low
Driver-side curtain air bag module (See 08-02-13
B2774
circuit resistance high DTC B1046,
24 19
Driver-side curtain air bag module B2773, B2774,
B2775 B2775, B2776.)
circuit short to body ground
Driver-side curtain air bag module
B2776
circuit short to power supply
Passenger-side curtain air bag
B2777
module circuit resistance low
Passenger-side curtain air bag
B2778
module circuit resistance high (See 08-02-35
Passenger-side curtain air bag DTC B1056,
25 18
B2779 module circuit short to body B2777, B2778,
ground B2779, B2780.)
Passenger-side curtain air bag
B2780 module circuit short to power
supply
(See 08-02-28
DTC B104D,
B2855 Crash zone sensor circuit short
42 11 B2226, B2227,
B2855.)
08-02
B2856 Crash zone sensor ID mismatch
Passenger-side side air bag (See 08-02-50
B2886 44 7 DTC B110E,
sensor No.1 ID mismatch
B110F, B2856,
Driver-side side air bag sensor B2886, B2887.)
B2887 43 8
No.1 ID mismatch
Seat track position sensor circuit
C1946
open
Seat track position sensor circuit
C1947
short to body ground (See 08-02-58
Seat track position sensor circuit DTC C1946,
C1948 49 22
resistance not within specification C1947, C1948,
Seat track position sensor circuit C1981, C1982.)
C1981
malfunction
Seat track position sensor circuit
C1982
short to power supply
(See 08-02-23
Driver-side side air bag sensor DTC B104B,
U2017 43 8
No. 1 (communication error) B104E, B1051,
U2017.)
(See 08-02-26
Passenger-side side air bag
DTC B104C,
U2018 44 7 sensor No. 1 (communication
B104F, B1050,
error)
U2018.)

U0073 14 4 CAN system communication error (See 09-02L-8

DTC TABLE
U0100 Communication error to PCM [MULTIPLEX
COMMUNICATIO
- - 1 Communication error to
U0155 N SYSTEM].)
instrument cluster

End Of Sie

08-02–9
1890-1U-06H(08-02).fm 10 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
PID/DATA MONITOR DISPLAY
id080200800700
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
— Select the “Toolbox” tab.
— Select “DataLogger”.
— Select “Modules”.
— Select “RCM”.
• When using the PDS (Pocket PC) DLC-2
— Select “Module Tests”.
— Select “RCM”.
— Select “DataLogger”.
ac9uuw00000635
3. Select the applicable PID from the PID table.
4. Verify the PID data according to the directions on
the screen.

Note
• The PID data screen function is used for monitoring the calculated value. Therefore, if the monitored value
of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually.

End Of Sie
PID/DATA MONITOR TABLE
id080200800800

PID name (definition) Unit/Condition Operation Condition (Reference) Terminal

BUCKLE_D
Unbuckled/ • Driver-side buckle switch off: Buckled
(Driver-side buckle switch 2W
Buckled • Driver-side buckle switch on: Unbuckled
status)
BUCKLE_P
Unbuckled/ • Passenger-side buckle switch off: Buckled
(Passenger-side buckle switch 2C
Buckled • Passenger-side buckle switch on: Unbuckled
status)
CCNT_RCM
⎯ Indicates number of DTC ⎯
(Number of continuous DTCs)
CRSH_RC
(Number of detected ⎯ Indicates number of detected collisions ⎯
collisions)
Starting/
DTC_CLR_ST*1 Normal End/
Fault information cleared at seat weight sensor 2AJ
(OCS DTC cleared state) In Process/
OCS Fault
IGN_V
V Ignition switch is at ON: B+ 1D
(IG1 voltage)
• Seat weight sensor calibration start-up: Starting
• Seat weight sensor calibration completed normally:
Normal End
Starting/ • Seat weight sensor calibration command being sent:
Normal End/ Commanding
Commanding/ • Voltage malfunction during seat weight sensor calibration:
OCS_CAL_ST*2 NG (Voltage)/ NG (Voltage)
(Seat weight sensor 2AJ
NG (Weight)/ • Weight error during seat weight sensor calibration: NG
calibration status) Timeout/ (Weight)
In Process/ • Seat weight sensor calibration time limit passed: Timeout
OCS Fault • Seat weight sensor calibration being processed: In
Process
• Seat weight sensor or Seat weight sensor control module
malfunction: OCS Fault
Empty/
SMALL/
OCS_SYS_ST*1 Indeterminate/
Occupant classification status determined by seat weight
2AJ
(Seat weight sensor status) sensor
LARGE/
Invalid

08-02–10
1890-1U-06H(08-02).fm 11 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
PID name (definition) Unit/Condition Operation Condition (Reference) Terminal
OCSFLT_CAL
OK/ • Sensor normal: OK
(Passenger sensing system 2AJ
FAULT • Seat weight sensor calibration error: FAULT
calibration status)
OCSFLT_COM • Sensor normal: OK
OK/
(Passenger sensing system • Seat weight sensor control module communication error: 2AJ
FAULT
communication status) FAULT
OCSFLT_L
OK/ • Sensor normal: OK
(Passenger sensing system 2AJ
FAULT • Seat weight sensor (LH) malfunction: FAULT
(LH) malfunction status)
OCSFLT_MDL
(Passenger sensing system OK/ • Sensor normal: OK
2AJ
control module malfunction FAULT • Seat weight sensor control module malfunction: FAULT
status)
OCSFLT_R
OK/ • Sensor normal: OK
(Passenger sensing system 2AJ
FAULT • Seat weight sensor (RH) malfunction: FAULT
(RH) malfunction status)
PS_WEIGHT
(Seat weight sensor measured kg Display of load (body weight) on front passenger-side seat 2AJ
weight of passenger)
• Passenger-side air bag module non-operation (non-
PSAB_DepSt
Inactive/ deployment) status: Inactive
(Passenger-side air bag 2AJ
Active • Passenger-side air bag module operation (deployment)
module deployment status)
enabled status: Active
RES_AB_D
(Driver-side air bag module ohm Under any condition: 1.5—9.7 ohms 1I, 1M 08-02
(inflator No.1) resistance)
RES_AB_P
(Passenger-side air bag
ohm Under any condition: 1.0—9.7 ohms 1J, 1N
module (inflator No.1)
resistance)
RES_AB2_D
(Driver-side air bag module ohm Under any condition: 1.5—9.7 ohms 1Q, 1U
(inflator No.2) resistance)
RES_AB2_P
(Passenger-side air bag
ohm Under any condition: 1.0—9.7 ohms 1R, 1V
module (inflator No.2)
resistance)
RES_CAB_D
(Driver-side curtain air bag ohm Under any condition: 1.0—9.7 ohms 2AG, 2AK
module resistance)
RES_CAB_P
(Passenger-side curtain air ohm Under any condition: 1.0—9.7 ohms 2AH, 2AL
bag module resistance)
RES_PT_D
(Driver-side pre-tensioner seat ohm Under any condition: 1.0—9.7 ohms 2N, 2J
belt resistance)
RES_PT_P
(Passenger-side pre-tensioner ohm Under any condition: 1.0—9.7 ohms 2A, 2E
seat belt resistance)
RES_SAB_D
(Driver-side side air bag ohm Under any condition: 1.0—9.7 ohms 2B, 2F
module resistance)
RES_SAB_P
(Passenger-side side air bag ohm Under any condition: 1.0—9.7 ohms 2I, 2M
module resistance)
TRAK_SW
Forward/ • Front seat front position: Forward
(Seat track position sensor 2AB, 2AF
Rearward • Front seat rear position: Rearward
state)
*1 : Used during seat weight sensor calibration setting. Not necessary for diagnostic.
*2
: When the calibration error is displayed, the error can be cleared by turning the ignition switch to the LOCK
position.
End Of Sie

08-02–11
1890-1U-06H(08-02).fm 12 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B1013
id080200800900

DTC B1013 Seat weight sensor calibration error

Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION
an operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.

• Calibration set value not within valid range.

• Weight acting on front passenger-side seat during calibration
• Improperly installed front passenger-side seat part at time of calibration
• Deformed floor where attached to front passenger-side seat
POSSIBLE • Deformed front passenger-side seat under-bracket or frame
CAUSE • Seat weight sensor deformed or malfunction
• Seat weight sensor control module malfunction
• SAS control module malfunction
• Load to or deformation of the seat belt rail

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT SEAT WEIGHT SENSOR Yes [Present malfunction diagnosis]
• Properly install the passenger-side front • Replace the SAS control module.
seat. (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Inspect the seat weight sensor. (See 08-10- INSTALLATION.)
13 SEAT WEIGHT SENSOR [Past malfunction diagnosis]
CALIBRATION.) • DTC troubleshooting completed.
• Is the seat weight sensor normal?
No Go to the next step.
2 INSPECT PASSENGER-SIDE FRONT SEAT Yes Replace any deformed parts or remove any foreign
• Turn the ignition switch to the LOCK position. objects.
• Disconnect the negative battery cable and • After replacement, perform seat weight sensor
wait for 1 min or more. calibration and reperform the DTC inspection. If the
• Remove the passenger-side seat and DTC is displayed, go the next step. (See 08-10-13
visually inspect for the following: SEAT WEIGHT SENSOR CALIBRATION.)
— Seat under-bracket deformation No Go to the next step.
— Seat frame deformation
— Seat weight sensor deformation
— Foreign objects stuck in seat
• Are any of the parts deformed or are any
foreign objects stuck in the seat?
3 INSPECT FLOOR Yes Go to the next step.
• Visually inspect the installation parts of the No Repair floor deformation.
front passenger-side seat for the following: • After repair, perform seat weight sensor calibration
— Abnormal floor deformation and reperform the DTC inspection. If the DTC is
— Installation hole of front passenger-side displayed even though the floor has been repaired, go
seat is improperly positioned the next step. (See 08-10-13 SEAT WEIGHT
• Is the floor normal? SENSOR CALIBRATION.)
4 INSPECT SEAT WEIGHT SENSOR CONTROL Yes Replace the seat weight sensor control module.
MODULE (See 08-10-12 SEAT WEIGHT SENSOR CONTROL
• Replace the seat weight sensor. MODULE REMOVAL/INSTALLATION.)
• After replacement, perform seat weight • After replacement, perform seat weight sensor
sensor calibration. (See 08-10-13 SEAT calibration and reperform the DTC inspection. If the
WEIGHT SENSOR CALIBRATION.) DTC is displayed even though the seat weight sensor
• Reperform the DTC inspection. control module has been replaced, replace the SAS
• Is DTC B1013 indicated? control module. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
No DTC troubleshooting completed.

End Of Sie

08-02–12
1890-1U-06H(08-02).fm 13 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B1046, B2773, B2774, B2775, B2776
id080200808900

B1046 Driver-side curtain air bag module and other air bag module circuits short
B2773 Driver-side curtain air bag module circuit resistance low
DTC B2774 Driver-side curtain air bag module circuit resistance high
B2775 Driver-side curtain air bag module circuit short to body ground
B2776 Driver-side curtain air bag module circuit short to power supply
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• Resistance other than 1.0—9.7 ohms detected in driver-side curtain air bag module circuit
• Malfunction in wiring harness between driver-side curtain air bag module and SAS control module
• Open or short circuit in wiring harness between driver-side curtain air bag module and SAS control
POSSIBLE module
CAUSE • Driver-side curtain air bag module malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR

DRIVER-SIDE CURTAIN AIR BAG MODULE

WIRING HARNESS-SIDE CONNECTOR
2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
B A
2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 08-02
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

08-02–13
1890-1U-06H(08-02).fm 14 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE CURTAIN AIR BAG Yes Replace the SAS control module.
MODULE (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-10 PID/DATA MONITOR
TABLE.)
— RES_CAB_D
• Is the resistance of the driver-side curtain air
bag module normal?
— Resistance: 1.0—9.7 ohms
2 INSPECT DRIVER-SIDE CURTAIN AIR BAG Yes Replace the air bag wiring harness.
MODULE CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the driver-side curtain air bag
module connector. (See 08-10-10 CURTAIN
AIR BAG MODULE REMOVAL/
INSTALLATION.)
• Is there any malfunction of the driver-side
curtain air bag module connector?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
DRIVER-SIDE CURTAIN AIR BAG MODULE No Replace the driver-side curtain air bag module.
OR RELATED WIRING HARNESS (See 08-10-10 CURTAIN AIR BAG MODULE REMOVAL/
• Connect the leads of the SST (Fuel and INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to driver-side curtain air bag
module connector terminals A and B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1046, B2773, B2774, B2775
and/or B2776 indicated?

08-02–14
1890-1U-06H(08-02).fm 15 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
4 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
DRIVER-SIDE CURTAIN AIR BAG MODULE (See 08-10-11 SAS CONTROL MODULE REMOVAL/
AND SAS CONTROL MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17- 08-02
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 2AK and driver-side
curtain air bag module terminal A, SAS
control module terminal 2AG and driver-side
curtain air bag module terminal B for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie

08-02–15
1890-1U-06H(08-02).fm 16 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B1047, B1992, B1993, B1994, B1995
id080200809000

B1047 Driver-side side air bag module and other air bag module circuits short
B1992 Driver-side side air bag module circuit short to power supply
DTC B1993 Driver-side side air bag module circuit short to body ground
B1994 Driver-side side air bag module circuit resistance high
B1995 Driver-side side air bag module circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• Resistance other than 1.0—9.7 ohms detected in driver-side side air bag module circuit
• Malfunction in wiring harness between driver-side side air bag module and SAS control module
• Open or short circuit in wiring harness between driver-side side air bag module and SAS control
POSSIBLE module
CAUSE • Driver-side side air bag module malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR

DRIVER-SIDE SIDE AIR BAG MODULE

WIRING HARNESS-SIDE CONNECTOR
2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B B A
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

08-02–16
1890-1U-06H(08-02).fm 17 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the SAS control module.
MODULE (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-10 PID/DATA MONITOR
TABLE.)
— RES_SAB_D
• Is the resistance of the driver-side side air
bag module normal?
— Resistance: 1.0—9.7 ohms
2 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
MODULE CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.) 08-02

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the driver-side side air bag
module connector. (See 08-10-8 SIDE AIR
BAG MODULE REMOVAL/INSTALLATION.)
• Is there any malfunction of the driver-side
side air bag module connector?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
DRIVER-SIDE SIDE AIR BAG MODULE OR No Replace the driver-side side air bag module.
RELATED WIRING HARNESS (See 08-10-8 SIDE AIR BAG MODULE REMOVAL/
• Connect the leads of the SST (Fuel and INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to driver-side side air bag module
connector terminals A and B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1047, B1992, B1993, B1994,
and/or B1995 indicated?

08-02–17
1890-1U-06H(08-02).fm 18 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
4 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
DRIVER-SIDE SIDE AIR BAG MODULE AND (See 08-10-11 SAS CONTROL MODULE REMOVAL/
SAS CONTROL MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the passenger-side front seat
connector. (See 09-13-3 FRONT SEAT
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 2F and driver-side
side air bag module terminal A, SAS control
module terminal 2B and driver-side side air
bag module terminal B for the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie
DTC B1048, B1925, B1933, B1935, B1938
id080200810600

B1048 Passenger-side air bag module (inflator No.1) and other air bag module circuits short
B1925 Passenger-side air bag module (inflator No.1) circuit short to power supply
DTC B1933 Passenger-side air bag module (inflator No.1) circuit resistance high
B1935 Passenger-side air bag module (inflator No.1) circuit resistance low
B1938 Passenger-side air bag module (inflator No.1) circuit short to body ground
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
inspection procedure.
CONDITION
• Resistance other than 1.0—9.7 ohms detected in passenger-side air bag module circuit (inflator No.1)
• Malfunction in wiring harness between passenger-side air bag module (inflator No.1) and SAS control
module
• Open or short circuit in wiring harness between passenger-side air bag module (inflator No.1) and SAS
POSSIBLE control module
CAUSE • Passenger-side air bag module malfunction
• SAS control module malfunction

08-02–18
1890-1U-06H(08-02).fm 19 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
B1048 Passenger-side air bag module (inflator No.1) and other air bag module circuits short
B1925 Passenger-side air bag module (inflator No.1) circuit short to power supply
DTC B1933 Passenger-side air bag module (inflator No.1) circuit resistance high
B1935 Passenger-side air bag module (inflator No.1) circuit resistance low
B1938 Passenger-side air bag module (inflator No.1) circuit short to body ground
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR PASSENGER-SIDE AIR BAG MODULE
WIRING HARNESS-SIDE CONNECTOR

1U 1Q 1M 1I 1E 1A
B A
1V 1R 1N 1J 1F 1B
1W 1S 1O 1K 1G 1C
1X 1T 1P 1L 1H 1D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the SAS control module.
MODULE (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-10 PID/DATA MONITOR 08-02
TABLE.)
— RES_AB_P
• Is the resistance of the passenger-side air
bag module normal?
— Resistance: 1.0—9.7 ohms
2 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the air bag wiring harness.
MODULE CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Is there any malfunction of the passenger-
side air bag module connector?

08-02–19
1890-1U-06H(08-02).fm 20 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
PASSENGER-SIDE AIR BAG MODULE OR No Replace the passenger-side air bag module.
RELATED WIRING HARNESS (See 08-10-7 PASSENGER-SIDE AIR BAG MODULE
• Connect the leads of the SST (Fuel and REMOVAL/INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to passenger-side air bag module
(inflator No.1) connector terminals 1A and
1B, and passenger-side air bag module
(inflator No.2) connector terminals 2A and
2B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1048, B1925, B1933, B1935
and/or B1938 indicated?
4 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
PASSENGER-SIDE AIR BAG MODULE AND (See 08-10-11 SAS CONTROL MODULE REMOVAL/
SAS CONTROL MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 1J and passenger-
side air bag module terminal 1A, SAS control
module terminal 1N and passenger-side air
bag module terminal 1B for the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie

08-02–20
1890-1U-06H(08-02).fm 21 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B1049, B1881, B1882, B1883, B1886
id080200810700

B1049 Passenger-side pre-tensioner seat belt and other air bag module circuits short
B1881 Passenger-side pre-tensioner seat belt circuit resistance high
DTC B1882 Passenger-side pre-tensioner seat belt circuit short to power supply
B1883 Passenger-side pre-tensioner seat belt circuit short to body ground
B1886 Passenger-side pre-tensioner seat belt circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• Resistance other than 1.0—9.7 ohms detected in passenger-side pre-tensioner seat belt circuit
• Malfunction in wiring harness between passenger-side pre-tensioner seat belt and SAS control module
• Open or short circuit in wiring harness between passenger-side pre-tensioner seat belt and SAS control
POSSIBLE module
CAUSE • Passenger-side pre-tensioner seat belt malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR
PASSENGER-SIDE PRE-TENSIONER SEAT
BELT WIRING HARNESS-SIDE CONNECTOR

2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A

B A
2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 08-02
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE PRE- Yes Replace the SAS control module.
TENSIONER SEAT BELT (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-10 PID/DATA MONITOR
TABLE.)
— RES_PT_P
• Is the resistance of the passenger-side pre-
tensioner seat belt normal?
— Resistance: 1.0—9.7 ohms

08-02–21
1890-1U-06H(08-02).fm 22 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT PASSENGER-SIDE PRE- Yes Replace the air bag wiring harness.
TENSIONER SEAT BELT CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the B-pillar lower trim (RH). (See
09-17-20 B-PILLAR LOWER TRIM
REMOVAL/INSTALLATION.)
• Disconnect the passenger-side pre-tensioner
seat belt connector. (See 08-11-2 FRONT
SEAT BELT REMOVAL/INSTALLATION.)
• Is there any malfunction of the passenger-
side pre-tensioner seat belt connector?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
PASSENGER-SIDE PRE-TENSIONER SEAT No Replace the passenger-side pre-tensioner seat belt.
BELT OR RELATED WIRING HARNESS (See 08-11-2 FRONT SEAT BELT REMOVAL/
• Connect the leads of the SST (Fuel and INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to passenger-side pre-tensioner
seat belt connector terminals A and B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1049, B1881, B1882, B1883,
and/or B1886 indicated?

08-02–22
1890-1U-06H(08-02).fm 23 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
4 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
PASSENGER-SIDE PRE-TENSIONER SEAT (See 08-10-11 SAS CONTROL MODULE REMOVAL/
BELT AND SAS CONTROL MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17- 08-02
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 2E and passenger-
side pre-tensioner seat belt terminal A, SAS
control module terminal 2A and passenger-
side pre-tensioner seat belt terminal B for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie
DTC B104B, B104E, B1051, U2017
id080200810800

B104B Driver-side side air bag sensor No.1 and other sensor circuits short to power supply
B104E Driver-side side air bag sensor No.1 circuit open or short
DTC
B1051 Driver-side side air bag sensor No.1 (internal circuit abnormal)
U2017 Driver-side side air bag sensor No.1 (communication error)
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• Malfunction in wiring harness between driver-side side air bag sensor No.1 and SAS control module
• Malfunction in driver-side side air bag sensor No.1 circuit
• Open or short circuit in wiring harness between driver-side side air bag sensor No.1 and SAS control
POSSIBLE module
CAUSE • Driver-side side air bag sensor No.1 malfunction
• SAS control module malfunction

08-02–23
1890-1U-06H(08-02).fm 24 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
B104B Driver-side side air bag sensor No.1 and other sensor circuits short to power supply
B104E Driver-side side air bag sensor No.1 circuit open or short
DTC
B1051 Driver-side side air bag sensor No.1 (internal circuit abnormal)
U2017 Driver-side side air bag sensor No.1 (communication error)
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR
DRIVER-SIDE SIDE AIR BAG SENSOR NO. 1
WIRING HARNESS-SIDE CONNECTOR

2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A

2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B B A
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
SENSOR NO.1 CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the driver-side side air bag
sensor No.1 connector.
• Is there any malfunction of the driver-side
side air bag sensor No.1 connector?

08-02–24
1890-1U-06H(08-02).fm 25 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the driver-side side air bag sensor No.1, then go
DRIVER-SIDE SIDE AIR BAG SENSOR NO.1 to the next step.
AND SAS CONTROL MODULE (See 08-10-14 SIDE AIR BAG SENSOR NO. 1
• Turn the ignition switch to the LOCK position. REMOVAL/INSTALLATION.)
• Disconnect the negative battery cable and No Replace the air bag wiring harness.
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17- 08-02
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Disconnect the driver-side side air bag
sensor No.1 connector.
• Inspect the wiring harnesses between SAS
control module terminal 2O and driver-side
side air bag sensor No.1 terminal A, SAS
control module terminal 2S and driver-side
side air bag sensor No.1 terminal B for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Connect the SAS control module connector. (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Connect the driver and passenger-side pre- INSTALLATION.)
tensioner seat belt connectors. No DTC troubleshooting completed.
• Connect the driver-side side air bag sensor
No.1 connector.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B104B, B104E, B1051 and/or
U2017 indicated?

End Of Sie

08-02–25
1890-1U-06H(08-02).fm 26 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B104C, B104F, B1050, U2018
id080200810900

B104C Passenger-side side air bag sensor No.1 and other sensor circuits short to power supply
B104F Passenger-side side air bag sensor No.1 (internal circuit abnormal)
DTC
B1050 Passenger-side side air bag sensor No.1 circuit open or short
U2018 Passenger-side side air bag sensor No.1 (communication error)
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
inspection procedure.
CONDITION
• Malfunction in wiring harness between passenger-side side air bag sensor No.1 and SAS control
module
• Malfunction in passenger-side side air bag sensor No.1 circuit
• Open or short circuit in wiring harness between passenger-side side air bag sensor No.1 and SAS
POSSIBLE control module
CAUSE • Passenger-side side air bag sensor No.1 malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR
PASSENGER-SIDE SIDE AIR BAG SENSOR NO. 1
WIRING HARNESS-SIDE CONNECTOR

2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A

2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B B A
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
SENSOR NO.1 CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the B-pillar lower trim (RH). (See
09-17-20 B-PILLAR LOWER TRIM
REMOVAL/INSTALLATION.)
• Disconnect the passenger-side side air bag
sensor No.1 connector. (See 08-10-14 SIDE
AIR BAG SENSOR NO. 1 REMOVAL/
INSTALLATION.)
• Is there any malfunction of the passenger-
side side air bag sensor No.1 connector?

08-02–26
1890-1U-06H(08-02).fm 27 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the passenger-side side air bag sensor No.1,
PASSENGER-SIDE SIDE AIR BAG SENSOR then go to the next step.
NO.1 AND SAS CONTROL MODULE (See 08-10-14 SIDE AIR BAG SENSOR NO. 1
• Turn the ignition switch to the LOCK position. REMOVAL/INSTALLATION.)
• Disconnect the negative battery cable and No Replace the air bag wiring harness.
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17- 08-02
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Disconnect the passenger-side side air bag
sensor No.1 connector.
• Inspect the wiring harnesses between SAS
control module terminal 2K and passenger-
side side air bag sensor No.1 terminal A,
SAS control module terminal 2G and
passenger-side side air bag sensor No.1
terminal B for the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Connect the SAS control module connector. (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Connect the driver and passenger-side pre- INSTALLATION.)
tensioner seat belt connectors. No DTC troubleshooting completed.
• Connect the passenger-side side air bag
sensor No.1 connector.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B104C, B104F, B1050 and/or
U2018 indicated?

End Of Sie

08-02–27
1890-1U-06H(08-02).fm 28 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B104D, B2226, B2227, B2855
id080200811000

B104D Crash zone sensor and other sensor circuits short to power supply
B2226 Crash zone sensor (internal circuit abnormal)
DTC
B2227 Crash zone sensor (communication error)
B2855 Crash zone sensor circuit short
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• Malfunction in wiring harness between crash zone sensor and SAS control module
• Malfunction in crash zone sensor circuit
• Open or short circuit in wiring harness between crash zone sensor and SAS control module
POSSIBLE
• Crash zone sensor malfunction
CAUSE
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR CRASH ZONE SENSOR WIRING
HARNESS-SIDE CONNECTOR

1U 1Q 1M 1I 1E 1A
1V 1R 1N 1J 1F 1B
B A
1W 1S 1O 1K 1G 1C
1X 1T 1P 1L 1H 1D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT CRASH ZONE SENSOR Yes Replace the air bag wiring harness.
CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the crash zone sensor connector.
(See 08-10-11 CRASH ZONE SENSOR
REMOVAL/INSTALLATION.)
• Is there any malfunction of the crash zone
sensor connector?

08-02–28
1890-1U-06H(08-02).fm 29 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the crash zone sensor, then go to the next step.
CRASH ZONE SENSOR AND SAS CONTROL (See 08-10-11 CRASH ZONE SENSOR REMOVAL/
MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17- 08-02
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harnesses between SAS
control module terminal 1W and crash zone
sensor terminal A, SAS control module
terminal 1S and crash zone sensor terminal
B for the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Connect the SAS control module connector. (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Connect the driver and passenger-side pre- INSTALLATION.)
tensioner seat belt connectors. No DTC troubleshooting completed.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Connect the crash zone sensor connector.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Is DTC B104D, B2226, B2227 and/or B2855
indicated?

End Of Sie

08-02–29
1890-1U-06H(08-02).fm 30 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B1054, B1877, B1878, B1879, B1885
id080200811200

B1054 Driver-side pre-tensioner seat belt and other air bag module circuits short
B1877 Driver-side pre-tensioner seat belt circuit resistance high
DTC B1878 Driver-side pre-tensioner seat belt circuit short to power supply
B1879 Driver-side pre-tensioner seat belt circuit short to body ground
B1885 Driver-side pre-tensioner seat belt circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• Resistance other than 1.0—9.7 ohms detected in driver-side pre-tensioner seat belt circuit
• Malfunction in the wiring harness between driver-side pre-tensioner seat belt and SAS control module
• Open or short circuit in wiring harness between driver-side pre-tensioner seat belt and SAS control
POSSIBLE module
CAUSE • Driver-side pre-tensioner seat belt malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR
DRIVER-SIDE PRE-TENSIONER SEAT BELT
WIRING HARNESS-SIDE CONNECTOR

2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A B A

2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

08-02–30
1890-1U-06H(08-02).fm 31 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE PRE-TENSIONER Yes Replace the SAS control module.
SEAT BELT (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-10 PID/DATA MONITOR
TABLE.)
— RES_PT_D
• Is the resistance of the driver-side pre-
tensioner seat belt normal?
— Resistance: 1.0—9.7 ohms
2 INSPECT DRIVER-SIDE PRE-TENSIONER Yes Replace the air bag wiring harness.
SEAT BELT CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.) 08-02

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the B-pillar lower trim (LH). (See 09-
17-20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver-side pre-tensioner seat
belt connector. (See 08-11-2 FRONT SEAT
BELT REMOVAL/INSTALLATION.)
• Is there any malfunction of the driver-side
pre-tensioner seat belt connector?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
DRIVER-SIDE PRE-TENSIONER SEAT BELT No Replace the driver-side pre-tensioner seat belt.
OR RELATED WIRING HARNESS (See 08-11-2 FRONT SEAT BELT REMOVAL/
• Connect the leads of the SST (Fuel and INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to driver-side pre-tensioner seat
belt connector terminals A and B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1054, B1877, B1878, B1879,
and/or B1885 indicated?

08-02–31
1890-1U-06H(08-02).fm 32 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
4 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
DRIVER-SIDE PRE-TENSIONER SEAT BELT (See 08-10-11 SAS CONTROL MODULE REMOVAL/
AND SAS CONTROL MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 2J and driver-side
pre-tensioner seat belt terminal A, SAS
control module terminal 2N and driver-side
pre-tensioner seat belt terminal B for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie
DTC B1055, B1996, B1997, B1998, B1999
id080200809400

B1055 Passenger-side side air bag module and other air bag module circuits short
B1996 Passenger-side side air bag module circuit short to power supply
DTC B1997 Passenger-side side air bag module circuit short to body ground
B1998 Passenger-side side air bag module circuit resistance high
B1999 Passenger-side side air bag module circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• Resistance other than 1.0—9.7 ohms detected in passenger-side side air bag module circuit
• Malfunction in wiring harness between passenger-side side air bag module and SAS control module
• Open or short circuit in wiring harness between passenger-side side air bag module and SAS control
POSSIBLE module
CAUSE • Passenger-side side air bag module malfunction
• SAS control module malfunction

08-02–32
1890-1U-06H(08-02).fm 33 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
B1055 Passenger-side side air bag module and other air bag module circuits short
B1996 Passenger-side side air bag module circuit short to power supply
DTC B1997 Passenger-side side air bag module circuit short to body ground
B1998 Passenger-side side air bag module circuit resistance high
B1999 Passenger-side side air bag module circuit resistance low
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR

PASSENGER-SIDE SIDE AIR BAG MODULE

WIRING HARNESS-SIDE CONNECTOR
2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B B A
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE SIDE AIR BAG Yes Replace the SAS control module.
MODULE (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
08-02
DATA monitor. No Go to the next step.
(See 08-02-10 PID/DATA MONITOR
TABLE.)
— RES_SAB_P
• Is the resistance of the passenger-side side
air bag module normal?
— Resistance: 1.0—9.7 ohms
2 INSPECT PASSENGER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
MODULE CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the passenger-side side air bag
module connector. (See 08-10-8 SIDE AIR
BAG MODULE REMOVAL/INSTALLATION.)
• Is there any malfunction of the passenger-
side side air bag module connector?

08-02–33
1890-1U-06H(08-02).fm 34 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
PASSENGER-SIDE SIDE AIR BAG MODULE No Replace the passenger-side side air bag module.
OR RELATED WIRING HARNESS (See 08-10-14 SIDE AIR BAG SENSOR NO. 1
• Connect the leads of the SST (Fuel and REMOVAL/INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to passenger-side side air bag
module connector terminals A and B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1055, B1996, B1997, B1998
and/or B1999 indicated?
4 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
PASSENGER-SIDE SIDE AIR BAG MODULE (See 08-10-11 SAS CONTROL MODULE REMOVAL/
AND SAS CONTROL MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver-side seat connector.
(See 09-13-3 FRONT SEAT REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 2I and passenger-
side side air bag module terminal A, SAS
control module terminal 2M and passenger-
side side air bag module terminal B for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie

08-02–34
1890-1U-06H(08-02).fm 35 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B1056, B2777, B2778, B2779, B2780
id080200809500

B1056 Passenger-side curtain air bag module and other air bag module circuits short
B2777 Passenger-side curtain air bag module circuit resistance low
DTC B2778 Passenger-side curtain air bag module circuit resistance high
B2779 Passenger-side curtain air bag module circuit short to body ground
B2780 Passenger-side curtain air bag module circuit short to power supply
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• Resistance other than 1.0—9.7 ohms detected in passenger-side curtain air bag module circuit
• Malfunction in wiring harness between passenger-side curtain air bag module and SAS control module
• Open or short circuit in wiring harness between passenger-side curtain air bag module and SAS control
POSSIBLE module
CAUSE • Passenger-side curtain air bag module malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR PASSENGER-SIDE CURTAIN AIR BAG MODULE
WIRING HARNESS-SIDE CONNECTOR

B A
2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 08-02
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE CURTAIN Yes Replace the SAS control module.
AIR BAG MODULE (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-10 PID/DATA MONITOR
TABLE.)
— RES_CAB_P
• Is the resistance of the passenger-side
curtain air bag module normal?
— Resistance: 1.0—9.7 ohms

08-02–35
1890-1U-06H(08-02).fm 36 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT PASSENGER-SIDE CURTAIN AIR Yes Replace the air bag wiring harness.
BAG MODULE CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the passenger-side curtain air
bag module connectors. (See 08-10-10
CURTAIN AIR BAG MODULE REMOVAL/
INSTALLATION.)
• Is there any malfunction of the passenger-
side curtain air bag module connector?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
PASSENGER-SIDE CURTAIN AIR BAG No Replace the passenger-side curtain air bag module.
MODULE OR RELATED WIRING HARNESS (See 08-10-10 CURTAIN AIR BAG MODULE REMOVAL/
• Connect the leads of the SST (Fuel and INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to passenger-side curtain air bag
module connector terminals A and B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1056, B2777, B2778, B2779
and/or B2780 indicated?

08-02–36
1890-1U-06H(08-02).fm 37 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
4 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
PASSENGER-SIDE CURTAIN AIR BAG (See 08-10-11 SAS CONTROL MODULE REMOVAL/
MODULE AND SAS CONTROL MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver-side curtain air bag
module connector. (See 08-10-10 CURTAIN
AIR BAG MODULE REMOVAL/
INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17- 08-02
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 2AL and passenger-
side curtain air bag module terminal A, SAS
control module terminal 2AH and passenger-
side curtain air bag module terminal B for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie
DTC B1057, B1916, B1932, B1934, B1936
id080200811300

B1057 Driver-side air bag module (inflator No.1) and other air bag module circuits short
B1916 Driver-side air bag module (inflator No.1) circuit short to power supply
DTC B1932 Driver-side air bag module (inflator No.1) circuit resistance high
B1934 Driver-side air bag module (inflator No.1) circuit resistance low
B1936 Driver-side air bag module (inflator No.1) circuit short to body ground
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
inspection procedure.
CONDITION
• Resistance other than 1.5—9.7 ohms detected in driver-side air bag module (inflator No.1) circuit
• Malfunction in wiring harness between driver-side air bag module (inflator No.1) and SAS control
module

08-02–37
1890-1U-06H(08-02).fm 38 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
B1057 Driver-side air bag module (inflator No.1) and other air bag module circuits short
B1916 Driver-side air bag module (inflator No.1) circuit short to power supply
DTC B1932 Driver-side air bag module (inflator No.1) circuit resistance high
B1934 Driver-side air bag module (inflator No.1) circuit resistance low
B1936 Driver-side air bag module (inflator No.1) circuit short to body ground
• Open or short circuit in wiring harness between clock spring and SAS control module
POSSIBLE • Clock spring malfunction
CAUSE • Driver-side air bag module malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING DRIVER-SIDE AIR BAG MODULE
HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR
CLOCK SPRING WIRING
(CLOCK SPRING )
HARNESS-SIDE CONNECTOR
(INFLATOR NO.1) (INFLATOR NO.2)
1U 1Q 1M 1I 1E 1A
1V 1R 1N 1J 1F 1B 3B 3A 4B 4A
1W 1S 1O 1K 1G 1C 1D 1C 1B 1A
1X 1T 1P 1L 1H 1D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the SAS control module.
• Using the M-MDS, verify the following PID/ (See 08-10-11 SAS CONTROL MODULE REMOVAL/
DATA monitor. INSTALLATION.)
(See 08-02-10 PID/DATA MONITOR TABLE.) No Go to the next step.
— RES_AB_D
• Is the resistance of the driver-side air bag
module (inflator No.1) normal?
— Resistance: 1.5—9.7 ohms
2 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the air bag wiring harness and /or clock spring.
CONNECTOR (CLOCK SPRING) No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the driver-side air bag module
connector. (See 08-10-6 DRIVER-SIDE AIR
BAG MODULE REMOVAL/INSTALLATION.)
• Is there any malfunction of the driver-side air
bag module (inflator No.1) connector?

08-02–38
1890-1U-06H(08-02).fm 39 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
DRIVER-SIDE AIR BAG MODULE OR No Replace the driver-side air bag module.
RELATED WIRING HARNESS (See 08-10-6 DRIVER-SIDE AIR BAG MODULE
• Connect the leads of the SST (Fuel and REMOVAL/INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to driver-side air bag module
(inflator No.1) connector terminals 3A and
3B, and driver-side air bag module (inflator
No.2) connector terminals 4A and 4B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1057, B1916, B1932, B1934
and/or B1936?
4 INSPECT CLOCK SPRING Yes Go to the next step.
• Inspect the clock spring. No Replace the clock spring.
(See 08-10-16 CLOCK SPRING (See 08-10-15 CLOCK SPRING REMOVAL/
INSPECTION.) INSTALLATION.)
• Is the clock spring normal?
5 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
CLOCK SPRING AND SAS CONTROL (See 08-10-11 SAS CONTROL MODULE REMOVAL/
MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more. 08-02
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 1M and clock spring
terminal 1D, SAS control module terminal 1I
and clock spring terminal 1C for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie

08-02–39
1890-1U-06H(08-02).fm 40 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B1058, B2228, B2230, B2232, B2234
id080200809600

B1058 Driver-side air bag module (inflator No.2) and other air bag module circuits short
B2228 Driver-side air bag module (inflator No.2) circuit short to body ground
DTC B2230 Driver-side air bag module (inflator No.2) circuit short to power supply
B2232 Driver-side air bag module (inflator No.2) circuit resistance high
B2234 Driver-side air bag module (inflator No.2) circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
inspection procedure.
CONDITION
• Resistance other than 1.5—9.7 ohms detected in driver-side air bag module (inflator No.2) circuit
• Malfunction in wiring harness between driver-side air bag module (inflator No.2) and SAS control
module
• Open or short circuit in wiring harness between clock spring and SAS control module
POSSIBLE • Clock spring malfunction
CAUSE • Driver-side air bag module malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING DRIVER-SIDE AIR BAG MODULE
HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR
CLOCK SPRING WIRING
(CLOCK SPRING )
HARNESS-SIDE CONNECTOR
(INFLATOR NO.1) (INFLATOR NO.2)
1U 1Q 1M 1I 1E 1A
1V 1R 1N 1J 1F 1B 3B 3A 4B 4A
1W 1S 1O 1K 1G 1C 1D 1C 1B 1A
1X 1T 1P 1L 1H 1D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the SAS control module.
(INFLATOR NO.2) (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-10 PID/DATA MONITOR
TABLE.)
— RES_AB2_D
• Is the resistance of the driver-side air bag
module normal?
— Resistance: 1.5—9.7 ohms

08-02–40
1890-1U-06H(08-02).fm 41 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the air bag wiring harness.
CONNECTOR (CLOCK SPRING) No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the air bag system service warnings
and cautions before handling the air
bag system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the driver-side air bag module
connector. (See 08-10-6 DRIVER-SIDE AIR
BAG MODULE REMOVAL/INSTALLATION.)
• Is there any malfunction of the driver-side air
bag module connector?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
DRIVER-SIDE AIR BAG MODULE (INFLATOR No Replace the driver-side air bag module.
08-02
NO.2) OR RELATED WIRING HARNESS (See 08-10-6 DRIVER-SIDE AIR BAG MODULE
• Connect the leads of the SST (Fuel and REMOVAL/INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to driver-side air bag module
(inflator No.1) connector terminals 3A and
3B, and driver-side air bag module (inflator
No.2) connector terminals 4A and 4B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1058, B2228, B2230, B2232
and/or B2234 indicated?
4 INSPECT CLOCK SPRING Yes Go to the next step.
• Inspect the clock spring. No Replace the clock spring.
(See 08-10-16 CLOCK SPRING (See 08-10-15 CLOCK SPRING REMOVAL/
INSPECTION.) INSTALLATION.)
• Is the clock spring normal?

08-02–41
1890-1U-06H(08-02).fm 42 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
5 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
CLOCK SPRING AND SAS CONTROL (See 08-10-11 SAS CONTROL MODULE REMOVAL/
MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 1Q and clock spring
terminal 1B, SAS control module terminal 1U
and clock spring terminal 1A for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie
DTC B1059, B2229, B2231, B2233, B2235
id080200809700

B1059 Passenger-side air bag module (inflator No.2) and other air bag module circuits short
B2229 Passenger-side air bag module (inflator No.2) circuit short to body ground
DTC B2231 Passenger-side air bag module (inflator No.2) circuit short to power supply
B2233 Passenger-side air bag module (inflator No.2) circuit resistance high
B2235 Passenger-side air bag module (inflator No.2) circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
inspection procedure.
CONDITION
• Resistance other than 1.0—9.7 ohms detected in passenger-side side air bag module circuit
• Malfunction in wiring harness between passenger-side air bag module (inflator No.2) and SAS control
module
• Open or short circuit in wiring harness between passenger-side air bag module (inflator No.2) and SAS
POSSIBLE control module
CAUSE • Passenger-side air bag module malfunction
• SAS control module malfunction

08-02–42
1890-1U-06H(08-02).fm 43 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
B1059 Passenger-side air bag module (inflator No.2) and other air bag module circuits short
B2229 Passenger-side air bag module (inflator No.2) circuit short to body ground
DTC B2231 Passenger-side air bag module (inflator No.2) circuit short to power supply
B2233 Passenger-side air bag module (inflator No.2) circuit resistance high
B2235 Passenger-side air bag module (inflator No.2) circuit resistance low
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR PASSENGER-SIDE AIR BAG MODULE WIRING
HARNESS-SIDE CONNECTOR
(INFLATOR NO.1) (INFLATOR NO.2)
1U 1Q 1M 1I 1E 1A
1V 1R 1N 1J 1F 1B 1B 1A 2B 2A
1W 1S 1O 1K 1G 1C
1X 1T 1P 1L 1H 1D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the SAS control module.
MODULE (INFLATOR NO.2) (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-10 PID/DATA MONITOR 08-02
TABLE.)
— RES_AB2_P
• Is the resistance of the passenger-side air
bag module normal?
— Resistance: 1.0—9.7 ohms
2 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the air bag wiring harness.
MODULE (INFLATOR NO.2) CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the air bag system service warnings
and cautions before handling the air
bag system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Is there any malfunction of the passenger-
side air bag module connector?

08-02–43
1890-1U-06H(08-02).fm 44 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
PASSENGER-SIDE AIR BAG MODULE No Replace the passenger-side air bag module.
(INFLATOR NO.2) OR RELATED WIRING (See 08-10-7 PASSENGER-SIDE AIR BAG MODULE
HARNESS REMOVAL/INSTALLATION.)
• Connect the leads of the SST (Fuel and
thermometer checker) or apply 2-ohm
resistance to passenger-side air bag module
(inflator No.1) connector terminals 1A and
1B, and passenger-side air bag module
(inflator No.2) connector terminals 2A and
2B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1059, B2229, B2231, B2233
and/or B2235 indicated?
4 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
PASSENGER-SIDE AIR BAG MODULE AND (See 08-10-11 SAS CONTROL MODULE REMOVAL/
SAS CONTROL MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module terminal 1V and passenger-
side air bag module terminal 2A, SAS control
module terminal 1R and passenger-side air
bag module terminal 2B for the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?

End Of Sie

08-02–44
1890-1U-06H(08-02).fm 45 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B105A
id080200811400

DTC B105A SAS control module activation (deployment) control frequency error
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection with only detection conditions may cause injury due to an
DETECTION operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• The SAS control module has enabled the air bag module or pre-tensioner seat belt to operate (deploy)
five times or more.
POSSIBLE
• SAS control module malfunction
CAUSE

Diagnostic procedure
ACTION
• Replace the SAS control module.
(See 08-10-11 SAS CONTROL MODULE REMOVAL/INSTALLATION.)

End Of Sie
DTC B105B, B110C, B1144, B1145
id080200812000

B105B Driver-side side air bag sensor No.2 and other sensor circuits short to power supply
B110C Driver-side side air bag sensor No.2 circuit open or short
DTC
B1144 Driver-side side air bag sensor No.2 (internal circuit abnormal)
B1145 Driver-side side air bag sensor No.2 (communication error) 08-02
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• Malfunction in wiring harness between driver-side side air bag sensor No.2 and SAS control module
• Malfunction in driver-side side air bag sensor No.2 circuit
• Open or short circuit in wiring harness between driver-side side air bag sensor No.2 and SAS control
POSSIBLE module
CAUSE • Driver-side side air bag sensor No.2 malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR
DRIVER-SIDE SIDE AIR BAG SENSOR NO. 2
WIRING HARNESS-SIDE CONNECTOR

2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A

2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B B A
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

08-02–45
1890-1U-06H(08-02).fm 46 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
SENSOR NO.2 CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the driver-side side air bag
sensor No.2 connector. (See 08-10-14 SIDE
AIR BAG SENSOR NO. 2 REMOVAL/
INSTALLATION.)
• Is there any malfunction of the driver-side
side air bag sensor No.2 connector?

08-02–46
1890-1U-06H(08-02).fm 47 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the driver-side side air bag sensor No.2, then go
DRIVER-SIDE SIDE AIR BAG SENSOR NO.2 to the next step.
AND SAS CONTROL MODULE (See 08-10-14 SIDE AIR BAG SENSOR NO. 2
• Turn the ignition switch to the LOCK position. REMOVAL/INSTALLATION.)
• Disconnect the negative battery cable and No Replace the air bag wiring harness.
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17- 08-02
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harnesses between SAS
control module terminal 2AM and driver-side
side air bag sensor No.2 terminal A, SAS
control module terminal 2AI and driver-side
side air bag sensor No.2 terminal B for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Connect the SAS control module connector. (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Connect the driver and passenger-side pre- INSTALLATION.)
tensioner seat belt connectors. No DTC troubleshooting completed.
• Connect the driver-side side air bag sensor
No.2 connector.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B105B, B110C, B1144 and/or
B1145 indicated?

End Of Sie

08-02–47
1890-1U-06H(08-02).fm 48 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B105F, B110D, B1146, B1147
id080200811900

B105F Passenger-side side air bag sensor No.2 and other sensor circuits short to power supply
B110D Passenger-side side air bag sensor No.2 circuit open or short
DTC
B1146 Passenger-side side air bag sensor No.2 (internal circuit abnormal)
B1147 Passenger-side side air bag sensor No.2 (communication error)
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
inspection procedure.
CONDITION
• Malfunction in wiring harness between passenger-side side air bag sensor No.2 and SAS control
module
• Malfunction in passenger-side side air bag sensor No.2 circuit
• Open or short circuit in wiring harness between passenger-side side air bag sensor No.2 and SAS
POSSIBLE control module
CAUSE • Passenger-side side air bag sensor No.2 malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR
PASSENGER-SIDE SIDE AIR BAG SENSOR NO. 2
WIRING HARNESS-SIDE CONNECTOR

2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A

2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B B A
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
SENSOR NO.2 CONNECTOR No Go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the passenger-side side air bag
sensor No.2 connector. (See 08-10-14 SIDE
AIR BAG SENSOR NO. 2 REMOVAL/
INSTALLATION.)
• Is there any malfunction of the passenger-
side side air bag sensor No.2 connector?

08-02–48
1890-1U-06H(08-02).fm 49 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the passenger-side side air bag sensor No.2,
PASSENGER-SIDE SIDE AIR BAG SENSOR then go to the next step.
NO.2 AND SAS CONTROL MODULE (See 08-10-14 SIDE AIR BAG SENSOR NO. 2
• Turn the ignition switch to the LOCK position. REMOVAL/INSTALLATION.)
• Disconnect the negative battery cable and No Replace the air bag wiring harness.
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17- 08-02
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harnesses between SAS
control module terminal 2AA and passenger-
side side air bag sensor No.2 terminal A,
SAS control module terminal 2AE and
passenger-side side air bag sensor No.2
terminal B for the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Connect the SAS control module connector. (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Connect the driver and passenger-side pre- INSTALLATION.)
tensioner seat belt connectors. No DTC troubleshooting completed.
• Connect the passenger-side side air bag
sensor No.2 connector.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B105F, B110D, B1146 and/or
B1147 indicated?

End Of Sie

08-02–49
1890-1U-06H(08-02).fm 50 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B110E, B110F, B2856, B2886, B2887
id080200811800

B110E Driver-side side air bag sensor No.2 ID mismatch

B110F Passenger-side side air bag sensor No.2 ID mismatch
DTC B2856 Crash zone sensor ID mismatch
B2886 Passenger-side side air bag sensor No.1 ID mismatch
B2887 Driver-side side air bag sensor No.1 ID mismatch
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.

• The SAS control module detects an error of impact magnitude set in the sensor, which occurs due to
installation mismatch of the crash zone sensor or side air bag sensors.
• Crash zone sensor misinstalled with wrong sensor
• Driver-side side air bag sensor No.1 misinstalled with wrong sensor
POSSIBLE
• Passenger-side side air bag sensor No.1 misinstalled with wrong sensor
CAUSE
• Driver-side side air bag sensor No.2 misinstalled with wrong sensor
• Passenger-side side air bag sensor No.2 misinstalled with wrong sensor

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT EACH SENSOR FOR Yes Go to the next step.
INSTALLATION POSITION No Install the each sensor correctly, then go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Verify that the crash zone sensor or side air
bag sensor is installed in the correct position.
• Is each sensor installed correctly?
2 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Connect the negative battery cable. (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Turn the ignition switch to the ON position. INSTALLATION.)
• Are DTCs B110E, B110F, B2856, B2886 No DTC troubleshooting completed.
and/or B2887 indicated?

End Of Sie

08-02–50
1890-1U-06H(08-02).fm 51 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B1231
id080200801000

DTC B1231 SAS control module activation (deployment) control freeze

Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection with only detection conditions may cause injury due to an
DETECTION
operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.

• SAS control module determined collision

Diagnostic procedure
ACTION
Replace the SAS control module.
(See 08-10-11 SAS CONTROL MODULE REMOVAL/INSTALLATION.)

End Of Sie
DTC B1317, B1318
id080200811500

B1317 SAS control module power supply voltage increases (18.1 V or more)
DTC
B1318 SAS control module power supply voltage decreases (less than 8 V)
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection with only detection conditions may cause injury due to an
DETECTION
operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.
08-02
• When the SAS control module power supply voltage is not within 8⎯18 V.
• Open or short circuit in wiring harness between battery and SAS control module
POSSIBLE • SAS 7.5 A fuse malfunction
CAUSE • Battery malfunction
• SAS control module malfunction
FUSE WIRING HARNESS-SIDE
CONNECTOR

W G
SAS CONTROL MODULE WIRING AM AF
HARNESS-SIDE CONNECTOR X Q H A
Y I
AN AG
Z R J B
1U 1Q 1M 1I 1E 1A
1V 1R 1N 1J 1F 1B AO AH AA S K
1W 1S 1O 1K 1G 1C AP AI AB L C
T
1X 1T 1P 1L 1H 1D AQ AJ AC M
AR AK AD U N D
AS AE V O E
AL
AT P F

08-02–51
1890-1U-06H(08-02).fm 52 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
Diagnostic procedure
Step Inspection Action
1 INSPECT FUSE Yes Go to the next step.
• Remove the SAS 7.5 A fuse. No Replace the fuse.
• Is the fuse normal?
2 INSPECT BATTERY Yes Go to the next step.
• Measure the battery positive voltage. No The battery has a malfunction.
• Is the voltage 8 V⎯18 V? Inspect the charge/discharge system.
3 INSPECT WIRING HARNESS BETWEEN Yes Install the fuse, then go to the next step.
BATTERY AND FUSE BLOCK No Repair the wiring harness between the battery and fuse
• Turn the ignition switch to the ON position. block.
• Measure the fuse block terminal H voltage.
• Is the voltage 8 V⎯18 V?
4 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
(See 08-10-11 SAS CONTROL MODULE REMOVAL/
Warning INSTALLATION.)
• Handling the air bag system No Repair the wiring harness between the fuse block and SAS
components improperly can control module.
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings before handling
the air bag system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Measure the voltage at the SAS control
module terminal 1D.
• Is the voltage 8 V⎯18 V?

End Of Sie

08-02–52
1890-1U-06H(08-02).fm 53 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B1342, B1921
id080200811700

B1342 SAS control module (internal circuit abnormal)

DTC
B1921 Air bag diagnostic ground circuit open
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection with only detection conditions may cause injury due to an
DETECTION
operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.

• Malfunction in the SAS control module internal circuit

POSSIBLE
• SAS control module malfunction
CAUSE

Diagnostic procedure
ACTION
• Replace the SAS control module.
(See 08-10-11 SAS CONTROL MODULE REMOVAL/INSTALLATION.)

End Of Sie
DTC B1868
id080200815000

DTC B1868 Air bag warning system light malfunction

Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection with only detection conditions may cause injury due to an 08-02
DETECTION
operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.

• Air bag warning system light malfunction.

Diagnostic Procedure
STEP INSPECTION ACTION
1 VERIFY THAT SAS CONTROL MODULE Yes Go to the next step.
CONNECTOR IS CONNECTED No Reconnect the connector properly, then go to the next step.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the air bag system service warnings
and cautions before handling the air
bag system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Are all SAS control module connectors
securely connected?
2 INSPECT DTCS IN SAS CONTROL MODULE Yes Perform the applicable DTC inspection.
• Inspect the DTC for the SAS control module (See 08-02-4 DTC TABLE.)
on-board diagnostic system. No Go to the next step.
• Has DTC U0155, U0073 been recorded in
memory?
3 INSPECT INSTRUMENT CLUSTER Yes Replace the SAS control module.
• Inspect the instrument cluster warning lights (See 08-10-11 SAS CONTROL MODULE REMOVAL/
using check code. INSTALLATION.)
(See 09-22-6 INSTRUMENT CLUSTER No Repair or replace the instrument cluster according to
INPUT/OUTPUT CHECK MODE.) inspection results.
• Are the check results okay?

08-02–53
1890-1U-06H(08-02).fm 54 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
End Of Sie

DTC B1884, B1890

id080200801600

B1884 Passenger air bag deactivation (PAD) indicator circuit open or short to body ground
DTC
B1890 Passenger air bag deactivation (PAD) indicator circuit short to power supply
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION
an operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.

• Malfunction in PAD indicator circuit

• Open or short circuit in wiring harness between information display and SAS control module
POSSIBLE • Open circuit in wiring harness between battery and information display
CAUSE • information display malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR SEAT WEIGHT SENSOR CONTROL MODULE
WIRING HARNESS-SIDE CONNECTOR

1U 1Q 1M 1I 1E 1A
1V 1R 1N 1J 1F 1B * * 3A
1W 1S 1O 1K 1G 1C * 3D 3B
1X 1T 1P 1L 1H 1D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT OPERATION OF PAD INDICATOR Yes Go to the next step.
• Turn the ignition switch to the ON position. No Go to Step 5.
• Does the PAD indicator illuminate?
2 INSPECT FUSE Yes Install the fuse, then go to the next step.
• Remove the MATER 10 A fuse. No Replace the fuse.
• Is the fuse normal?
3 INSPECT BATTERY Yes Go to the next step.
• Measure the battery positive voltage. No Battery is malfunctioning
• Is the voltage 9 V⎯16 V? Inspect the charge/discharge system.
4 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
BATTERY AND PAD INDICATOR No Repair the wiring harness between the battery and
• Turn the ignition switch to the ON position. information display.
• Measure the information display connector
terminal E voltage.
• Is the voltage 9 V or more?

08-02–54
1890-1U-06H(08-02).fm 55 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
5 INSPECT WIRING HARNESS BETWEEN PAD Yes Go to the next step.
INDICATOR AND SAS CONTROL MODULE No Replace the air bag wiring harness.

Warning
• Handling the air bag system components
improperly can accidentally deploy the air
bag modules and pre-tensioner front
buckles, which may seriously injure you.
Read the service warnings before handling
the air bag system components.
(See 08-10-3 AIR BAG SYSTEM SERVICE
WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM SERVICE
CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and wait
for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/INSTALLATION.)
• Disconnect the clock spring connector. (See 09-
18-16 COMBINATION SWITCH REMOVAL/
INSTALLATION.)
• Remove the glove compartment. (See 09-17-9
GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag module 08-02
connector. (See 08-10-7 PASSENGER-SIDE
AIR BAG MODULE REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side front
seat connectors. (See 09-13-3 FRONT SEAT
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-10-
10 CURTAIN AIR BAG MODULE REMOVAL/
INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-20 B-
PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side pre-
tensioner seat belt connectors. (See 08-11-2
FRONT SEAT BELT REMOVAL/INSTALLATION.)
• Disconnect the SAS control module connectors.
(See 08-10-11 SAS CONTROL MODULE
REMOVAL/INSTALLATION.)
• Inspect the wiring harness between information
display connector terminal K and SAS control
module connector terminal 1G for the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
6 INSPECT PAD INDICATOR Yes Replace the information display.
• Disconnect the SAS control module connector. (See 09-22-14 INFORMATION DISPLAY REMOVAL/
• Connect the information display connector. INSTALLATION.)
• Does the PAD indicator illuminate? No Replace the SAS control module.
(See 08-10-11 SAS CONTROL MODULE REMOVAL/
INSTALLATION.)

End Of Sie

08-02–55
1890-1U-06H(08-02).fm 56 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC B2290
id080200802300

DTC B2290 Seat weight sensor signal malfunction

Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION
an operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.

• Passenger sensing system circuit malfunction

• Seat weight sensor calibration not properly set
POSSIBLE • Communication error between SAS control module and seat weight sensor control module
CAUSE • Seat weight sensor control module internal malfunction
• LH or RH seat weight sensor malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR
SEAT WEIGHT SENSOR CONTROL MODULE
WIRING HARNESS-SIDE CONNECTOR

2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A

2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B * * 3A
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C * 3D 3B
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

STEP INSPECTION ACTION

1 INSPECT SEAT WEIGHT SENSOR CONTROL Yes Repair or replace the wiring harness.
MODULE CONNECTOR After replacement, reperform the DTC inspection and
verify that no DTCs are displayed.
Warning No Go to the next step.
• Handling the air bag system
components improperly can
accidentally operate (deploy) the air
bag modules and pre-tensioner seat
belts, which may seriously injure you.
Read the service warnings and
cautions before handling the air bag
system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the seat weight sensor control
module connector. (See 08-10-12 SEAT
WEIGHT SENSOR CONTROL MODULE
REMOVAL/INSTALLATION.)
• Is there any malfunction of the seat weight
sensor control module connector?
2 INSPECT SEAT WEIGHT SENSOR CONTROL Yes Go to the next step.
MODULE POWER SUPPLY CIRCUIT No If there is any malfunction in the wiring harnesses, repair
• Turn the ignition switch to the ON position. or replace the applicable wiring harness.
• Measure voltage at terminal 3A of seat After replacement, reperform the DTC inspection and
weight sensor control module connector. verify that no DTCs are displayed.
• Is voltage more than B+?

08-02–56
1890-1U-06H(08-02).fm 57 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 INSPECTION WIRING HARNESS Yes Go to the next step.
• Disconnect the SAS control module No If there is any malfunction in the wiring harnesses, repair
connector. (See 08-10-11 SAS CONTROL or replace the applicable wiring harness.
MODULE REMOVAL/INSTALLATION.) After replacement, reperform the DTC inspection and
• Verify continuity in the following wiring verify that no DTCs are displayed.
harnesses:
— Between SAS control module terminal 2AJ
and seat weight sensor control module
terminal 3D
— Between seat weight sensor control module
terminal 3B and body ground
• Is the continuity normal?
4 INSPECT PASSENGER SENSING SYSTEM Yes Go to the next step.
• Connect the seat weight sensor control No Replace the following parts according to the M-MDS
module connector. screen:
• Connect the SAS control module. • If OCSFLT_CAL is displayed:
• Connect the negative battery cable. — Perform seat weight sensor calibration (See 08-10-
• Verify the following PIDs using the M-MDS. 13 SEAT WEIGHT SENSOR CALIBRATION.)
(See 08-02-10 PID/DATA MONITOR TABLE.) • If OCSFLT_COM or OCSFLT_MDL is displayed:
— OCSFLT_CAL — Seat weight sensor control module (See 08-10-12
— OCSFLT_COM SEAT WEIGHT SENSOR CONTROL MODULE
— OCSFLT_L REMOVAL/INSTALLATION.)
— OCSFLT_MDL • If OCSFLT_L is displayed:
— OCSFLT_R — Seat weight sensor (LH) (See: 09-13-3 FRONT
• Do all PIDs display “OK”? SEAT DISASSEMBLY/ASSEMBLY.)
• If OCSFLT_R is displayed:
— Seat weight sensor (RH) (See 09-13-3 FRONT 08-02
SEAT DISASSEMBLY/ASSEMBLY.)
5 INSPECT SAS CONTROL MODULE Yes [Present malfunction diangnosis]
• Reperform the DTC inspection. • Replace the SAS control module.
• Is DTC B2290 indicated? (See 08-10-11 SAS CONTROL MODULE REMOVAL/
INSTALLATION.)
[Past malfunction diagnosis]
• DTC troubleshooting completed.
No DTC troubleshooting completed.

End Of Sie
DTC B2477
id080200810500

DTC B2477 Configuration error

Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION
an operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.

• SAS control module configuration has not been performed correctly.

POSSIBLE • SAS control module configuration error
CAUSE • SAS control module malfunction

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Using the M-MDS, perform SAS control (See 08-10-11 SAS CONTROL MODULE REMOVAL/
module configuration. (See 08-10-12 SAS INSTALLATION.)
CONTROL MODULE CONFIGURATION.) No DTC troubleshooting completed.
• Is DTC B2477 indicated?

End Of Sie

08-02–57
1890-1U-06H(08-02).fm 58 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
DTC C1946, C1947, C1948, C1981, C1982
id080200820200

C1946 Seat track position sensor circuit open

C1947 Seat track position sensor circuit short to body ground
DTC C1948 Seat track position sensor circuit resistance not within specification
C1981 Seat track position sensor circuit malfunction
C1982 Seat track position sensor circuit short to power supply
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION
an operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.

• Malfunction in seat track position sensor circuit.

• Malfunction of connector between seat track position sensor and SAS control module.
POSSIBLE • Open or short circuit in wiring harness between seat track position sensor and SAS control module.
CAUSE • Seat track position sensor malfunction
• SAS control module malfunction

SAS CONTROL MODULE WIRING

HARNESS-SIDE CONNECTOR

SEAT TRACK POSITION SENSOR

WIRING HARNESS-SIDE CONNECTOR
2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B A C
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
* *
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT SEAT TRACK POSITION SENSOR Yes [Present malfunction diagnosis]
CIRCUIT • Replace the SAS control module.
• Using the M-MDS, verify the following PID/ (See 08-10-11 SAS CONTROL MODULE REMOVAL/
DATA monitor. INSTALLATION.)
(See 08-02-10 PID/DATA MONITOR TABLE.) [Past malfunction diagnosis]
— TRAK_SW • DTC troubleshooting completed.
• Is the seat track position sensor circuit
No Go to next step.
normal?

08-02–58
1890-1U-06H(08-02).fm 59 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the seat track position sensor, then go to next step.
SEAT TRACK POSITION SENSOR AND SAS No Replace wiring harness, then go to next step.
CONTROL MODULE

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the air bag system service warnings
and cautions before handling the air
bag system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to the LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.) 08-02
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Disconnect the seat track position sensor
connector
• Inspect the wiring harness between SAS
control module terminal and seat track
position sensor terminals for short to ground,
short to power supply, and open circuit:
— 2AB—A
— 2AF—C
• Is the wiring harness normal?

08-02–59
1890-1U-06H(08-02).fm 60 ページ ２００６年１２月１９日　火曜日　午後１時５分

ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 INSPECT SAS CONTROL MODULE Yes [Present malfunction diagnosis]
• Connect the SAS control module connector. • Replace the SAS control module.
• Connect the clock spring connector. (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Connect the passenger-side air bag module INSTALLATION.)
connector. [Past malfunction diagnosis]
• Connect the driver-and passenger-side front • DTC troubleshooting completed.
seat connectors.
• Connect the driver-and passenger-side No DTC troubleshooting completed.
curtain air bag module connectors.
• Connect the driver-and passenger-side pre
tensioner seat belt connectors.
• Connect the seat track position sensor
connector.
• Are DTCs C1946, C1947, C1948, C1981
and/or C1982 indicated?

End Of Sie

08-02–60
1890-1U-06H(08-03).fm 1 ページ ２００６年１２月１９日　火曜日　午後１時７分

SYMPTOM TROUBLESHOOTING
08-03 SYMPTOM TROUBLESHOOTING
AIR BAG SYSTEM WIRING DIAGRAM Diagnostic Procedure . . . . . . . . . . . . . . 08-03–3
(SYMPTOM NO.2 AIR BAG SYSTEM WARNING
TROUBLESHOOTING) . . . . . . . . . . . . . 08-03–2 LIGHT ILLUMINATES
TROUBLESHOOTING INDEX. . . . . . . . . 08-03–3 CONSTANTLY . . . . . . . . . . . . . . . . . . . . 08-03–5
NO.1 AIR BAG SYSTEM WARNING Diagnostic Procedure . . . . . . . . . . . . . . 08-03–5
LIGHT DOES NOT ILLUMINATE . . . . . 08-03–3

End of Toc
WM: AIR BAG SYSTEM

08-03

08-03–1
1890-1U-06H(08-03).fm 2 ページ ２００６年１２月１９日　火曜日　午後１時７分

SYMPTOM TROUBLESHOOTING
AIR BAG SYSTEM WIRING DIAGRAM (SYMPTOM TROUBLESHOOTING)
id080300805300

IG1
CLOCK SPRING

1D 1I 1C 3B INFLATOR
NO.1
1X 1M 1D 3A
DRIVER-SIDE
TO CAN SYSTEM-
RELATED UNIT AIR BAG
1T MODULE
1U 1A 4B
INFLATOR
NO.2
1Q 1B 4A

INSTRUMENT
CLUSTER

1J 1A INFLATOR
SEAT TRACK A 2AB NO.1
POSITION 1N 1E
SENSOR C 2AF PASSENGER-SIDE
IG1
AIR BAG MODULE
INFORMATION 1V 2A
1G INFLATOR
DISPLAY NO.2
1R 2B
TWISTED
IG1
SEAT PAIR
WEIGHT 1A
SENSOR 1B SEAT 3A
(LH) WEIGHT 2J A DRIVER-SIDE
SENSOR 3D PRE-TENSIONER
2AJ
SEAT 2N B SEAT BELT
CONTROL
WEIGHT 2A
MODULE 3B
SENSOR 2B
(RH) SAS 2AK A DRIVER-SIDE
CONTROL CURTAIN AIR BAG
A 1W MODULE
CRASH ZONE 2AG B MODULE
SENSOR B 1S
TWISTED PAIR
2F A
A 2W DRIVER-SIDE SIDE
DRIVER-SIDE
AIR BAG MODULE
BUCKLE SWITCH B 2B B

PASSENGER-SIDE A 2C
BUCKLE SWITCH B 2E A PASSENGER-SIDE
PRE-TENSIONER
A 2O 2A B SEAT BELT
DRIVER-SIDE SIDE AIR
BAG SENSOR No. 1 2S
B
2AL A PASSENGER-SIDE
A 2K CURTAIN AIR BAG
PASSENGER-SIDE SIDE
2AH B MODULE
AIR BAG SENSOR No. 1 2G
B

A 2AM 2I A
DRIVER-SIDE SIDE AIR PASSENGER-SIDE
BAG SENSOR No. 2 2AI SIDE AIR BAG
B 2M B

A 2AA
PASSENGER-SIDE SIDE
AIR BAG SENSOR No. 2 B 2AE
TWISTED PAIR
1K

2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1U 1Q 1M 1I 1E 1A

2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1V 1R 1N 1J 1F 1B
2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1W 1S 1O 1K 1G 1C
2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1X 1T 1P 1L 1H 1D

ac9uuw00002217
End Of Sie

08-03–2
1890-1U-06H(08-03).fm 3 ページ ２００６年１２月１９日　火曜日　午後１時７分

SYMPTOM TROUBLESHOOTING
TROUBLESHOOTING INDEX
id080300802000
• Use the chart below verify the symptoms of the trouble in order to diagnose the appropriate area.
No. Troubleshooting item Description Page
1 Air bag system warning light does not Malfunction in air bag system warning (See 08-03-3 NO.1 AIR BAG SYSTEM
illuminate. light circuit (short to ground). WARNING LIGHT DOES NOT
ILLUMINATE)
2 Air bag system warning light is Malfunction in air bag system warning (See 08-03-5 NO.2 AIR BAG SYSTEM
illuminated constantly. light circuit (open circuit or short to WARNING LIGHT ILLUMINATES
power supply). CONSTANTLY)

End Of Sie
NO.1 AIR BAG SYSTEM WARNING LIGHT DOES NOT ILLUMINATE
id080300800200

1 Air bag system warning light does not illuminate.

DETECTION Malfunction in air bag system warning light circuit (short to ground)
CONDITION
• SAS control module malfunction
POSSIBLE
• Instrument cluster (circuit board) malfunction
CAUSE
• Short to ground circuit in wiring harness between instrument cluster and SAS control module

Diagnostic Procedure
STEP INSPECTION ACTION
1 INSPECT OTHER WARNING AND INDICATOR Yes Turn the ignition switch to the LOCK position, then go to the
LIGHTS CIRCUIT IN INSTRUMENT CLUSTER next step.
• Turn the ignition switch to the ON position. No Inspect the instrument cluster power supply system and 08-03
• Do other warning and indicator lights ground system, then go to Step 4.
illuminate?
2 INSPECT DTCS IN SAS CONTROL MODULE Yes Perform the applicable DTC inspection, then go to Step 5.
• Inspect the DTC for the SAS control module (See 08-02-4 DTC TABLE.)
on-board diagnostic system. No Go to the next step.
• Have DTCs been recorded in memory?

08-03–3
1890-1U-06H(08-03).fm 4 ページ ２００６年１２月１９日　火曜日　午後１時７分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module, then go to Step 5.
(See 08-10-11 SAS CONTROL MODULE REMOVAL/
Warning INSTALLATION.)
• Handling the air bag system No Go to the next step.
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the air bag system service warnings
and cautions before handling the air
bag system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Connect the negative battery cable.
• Turn the ignition switch to ON position.
• Does the air bag system warning light
illuminate?
4 INSPECT DTCS IN INSTRUMENT CLUSTER Yes Perform the applicable DTC inspection, then go to the next
• Inspect the DTC for the instrument cluster step.
on-board diagnostic system. (See 09-02J-2 DTC TABLE [INSTRUMENT CLUSTER].)
• Have DTCs been recorded in memory? No Inspect the instrument cluster warning lights using check
code, then go to the next step.
(See 09-22-6 INSTRUMENT CLUSTER INPUT/OUTPUT
CHECK MODE.)

08-03–4
1890-1U-06H(08-03).fm 5 ページ ２００６年１２月１９日　火曜日　午後１時７分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
5 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Complete troubleshooting, then explain repairs to customer.
DO NOT RECUR AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Turn the ignition switch to LOCK position. malfunction recurs.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Connect all SAS control module connectors.
• Connect the driver and passenger-side
pre-tensioner seat belt connectors.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Connect the negative battery cable.
• Turn the ignition switch to ON position.
• Does the air bag system warning light
operate properly?

End Of Sie
NO.2 AIR BAG SYSTEM WARNING LIGHT ILLUMINATES CONSTANTLY
id080300800300

2 Air bag system warning light is illuminated constantly.

DETECTION Malfunction in air bag system warning light circuit (open circuit or short to power supply).
CONDITION 08-03
• Weak battery
• SAS control module malfunction
• Instrument cluster (circuit board) malfunction
• No connection in SAS control module connector
POSSIBLE • Poor contact in instrument cluster connector
CAUSE • Open or short to power supply circuit in wiring harness between instrument cluster and SAS control
module
• Poor contact at terminals 1D and/or 1K of SAS control module connector
• Poor contact in wiring harness between terminal 1K of SAS control module connector and ground
• Poor contact in wiring harness between battery and terminal 1D of SAS control module

Diagnostic Procedure
STEP INSPECTION ACTION
1 INSPECT BATTERY Yes Go to the next step.
• Measure the voltage of battery. No Battery is weak.
• Is the voltage 9 V or more? Inspect charge/discharge system, then go to Step 10.
(See 01-17-2 BATTERY INSPECTION [MZI-3.5].)

08-03–5
1890-1U-06H(08-03).fm 6 ページ ２００６年１２月１９日　火曜日　午後１時７分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
2 VERIFY THAT SAS CONTROL MODULE Yes Go to the next step.
CONNECTOR IS CONNECTED No Reconnect the connector properly, then go to Step 10.

Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the air bag system service warnings
and cautions before handling the air
bag system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)

• Turn the ignition switch to LOCK position.

• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the console. (See 09-17-16
CONSOLE REMOVAL/INSTALLATION.)
• Are all SAS control module connectors
securely connected?
3 INSPECT DTCS IN INSTRUMENT CLUSTER Yes Go to the next step.
• Inspect the DTC for the instrument cluster No Inspect the instrument cluster. (See 09-22-5 INSTRUMENT
on-board diagnostic system. CLUSTER INSPECTION.)
• Has DTC U2064 been recorded in memory?
4 INSPECT DTCS IN SAS CONTROL MODULE Yes Perform the applicable DTC inspection, then go to Step 10.
• Inspect the DTC for the SAS control module (See 08-02-4 DTC TABLE.)
on-board diagnostic system. No Go to the next step.
• Have DTCs been recorded in memory?
5 INSPECT DTCS IN INSTRUMENT CLUSTER Yes Perform the applicable DTC inspection, then go to Step 10.
• Inspect the DTC for the instrument cluster (See 09-02J-3 CLEARING DTC [INSTRUMENT
on-board diagnostic system. CLUSTER].)
• Have DTCs been recorded in memory? No Go to the next step.
6 INSPECT INSTRUMENT CLUSTER Yes Go to the next step.
• Inspect the instrument cluster warning lights No Repair or replace the instrument cluster according to
using check code. inspection results.
(See 09-22-6 INSTRUMENT CLUSTER Then go to Step 10.
INPUT/OUTPUT CHECK MODE.)
• Are the check results okay?
7 INSPECT POWER SUPPLY CIRCUIT OF SAS Yes Go to the Step 9.
CONTROL MODULE (TERMINAL 1D) No Go to the next step.
• Turn the ignition switch to LOCK position.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Connect all SAS control module connectors.
• Connect the driver and passenger-side
pre-tensioner seat belt connectors.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Inspect the voltage for PID/DATA monitor
IGN_V_2 item using M-MDS.
• Is the voltage of at least one terminal 8 V—
16 V?

08-03–6
1890-1U-06H(08-03).fm 7 ページ ２００６年１２月１９日　火曜日　午後１時７分

SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
8 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
BATTERY AND FUSE BLOCK No Repair the wiring harnesses, then go to Step 10.
• Connect the negative battery cable.
• Turn the ignition switch to ON position.
• Measure the voltage at instrument cluster
connector terminal 1H.
• Is the voltage 8 V—16 V?
9 VERIFY THAT SAS CONTROL MODULE Yes Replace the SAS control module, then go to the next step.
CONNECTOR TERMINAL 1D IS GROUND (See 08-10-11 SAS CONTROL MODULE REMOVAL/
• Turn the ignition switch to LOCK position. INSTALLATION.)
• Disconnect the negative battery cable and No Replace the wiring harnesses, then go to the next step.
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector. (See
09-18-16 COMBINATION SWITCH
REMOVAL/INSTALLATION.)
• Remove the glove compartment. (See 09-17-
9 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector. (See 08-10-7
PASSENGER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
front seat connectors. (See 09-13-3 FRONT 08-03
SEAT REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors. (See 08-
10-10 CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION.)
• Remove the B-pillar lower trim. (See 09-17-
20 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors. (See 08-
11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connectors. (See 08-10-11 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
• Inspect the wiring harness between SAS
control module connector terminal 1D and
ground for the following:
— Short to power supply
— Open circuit
• Is the wiring harness normal?
10 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Complete troubleshooting, then explain repairs to customer.
DO NOT RECUR AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Turn the ignition switch to LOCK position. malfunction recurs.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Connect all SAS control module connectors.
• Connect the driver and passenger-side pre-
tensioner seat belt connectors.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Connect the instrument cluster connector.
• Connect the negative battery cable.
• Turn the ignition switch to ON position.
• Does the air bag system warning light
operate properly?

08-03–7
1890-1U-06H(08-10).fm 1 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

08-10 AIR BAG SYSTEM
AIR BAG SYSTEM SEAT WEIGHT SENSOR CONTROL
LOCATION INDEX. . . . . . . . . . . . . . . . . 08-10–2 MODULE
AIR BAG SYSTEM SERVICE REMOVAL/INSTALLATION . . . . . . . . . . 08-10–12
WARNINGS . . . . . . . . . . . . . . . . . . . . . . 08-10–3 SEAT WEIGHT SENSOR
Air Bag Module Inspection . . . . . . . . . . 08-10–3 CALIBRATION . . . . . . . . . . . . . . . . . . . . 08-10–13
Air Bag Module Handling . . . . . . . . . . . 08-10–3 SEAT WEIGHT SENSOR
Side Air Bag Module Handling . . . . . . . 08-10–3 INSPECTION . . . . . . . . . . . . . . . . . . . . . 08-10–13
Seat Weight Sensor Handling . . . . . . . 08-10–4 SIDE AIR BAG SENSOR NO. 1
SAS Control Module Handling . . . . . . . 08-10–4 REMOVAL/INSTALLATION . . . . . . . . . . 08-10–14
Crash Zone Sensor Handling. . . . . . . . 08-10–4 SIDE AIR BAG SENSOR NO. 2
Side Air Bag Sensor Handling . . . . . . . 08-10–4 REMOVAL/INSTALLATION . . . . . . . . . . 08-10–14
Pre-tensioner Seat CLOCK SPRING
Belt Inspection . . . . . . . . . . . . . . . . . . 08-10–5 REMOVAL/INSTALLATION . . . . . . . . . . 08-10–15
AIR BAG SYSTEM SERVICE CLOCK SPRING ADJUSTMENT . . . . . . . 08-10–15
CAUTIONS . . . . . . . . . . . . . . . . . . . . . . 08-10–5 CLOCK SPRING INSPECTION . . . . . . . . 08-10–16
Air Bag System Component AIR BAG MODULE AND
Disassembly. . . . . . . . . . . . . . . . . . . . 08-10–5 PRE-TENSIONER SEAT BELT
Air Bag Module, Pre-tensioner Seat DEPLOYMENT PROCEDURES . . . . . . . 08-10–17
Belt Handling . . . . . . . . . . . . . . . . . . . 08-10–5 Deployment Procedure for
Seat Weight Sensor Handling . . . . . . . 08-10–5 Inside of Vehicle . . . . . . . . . . . . . . . . . 08-10–17
Air Bag Module, Pre-tensioner Seat Driver-side Air Bag Module . . . . . . . . . . 08-10–17
Belt Reuse . . . . . . . . . . . . . . . . . . . . . 08-10–6 Passenger-side Air Bag Module . . . . . . 08-10–18
Air Bag Wiring Harness Repair . . . . . . 08-10–6 Side Air Bag Module . . . . . . . . . . . . . . . 08-10–19
DRIVER-SIDE AIR BAG MODULE Curtain Air Bag Module . . . . . . . . . . . . . 08-10–20 08-10
REMOVAL/INSTALLATION. . . . . . . . . . 08-10–6 Pre-tensioner Seat Belt . . . . . . . . . . . . . 08-10–20
Connector A Removal Note . . . . . . . . . 08-10–6 Deployment Procedure for
PASSENGER-SIDE AIR BAG MODULE Outside of Vehicle . . . . . . . . . . . . . . . . 08-10–21
REMOVAL/INSTALLATION. . . . . . . . . . 08-10–7 Driver-side Air Bag Module . . . . . . . . . . 08-10–21
SIDE AIR BAG MODULE Passenger-side Air Bag Module . . . . . . 08-10–23
REMOVAL/INSTALLATION. . . . . . . . . . 08-10–8 Side Air Bag Module . . . . . . . . . . . . . . . 08-10–25
CURTAIN AIR BAG MODULE Curtain Air Bag Module . . . . . . . . . . . . . 08-10–27
REMOVAL/INSTALLATION. . . . . . . . . . 08-10–10 Pre-tensioner Seat Belt . . . . . . . . . . . . . 08-10–29
CRASH ZONE SENSOR AIR BAG MODULE AND
REMOVAL/INSTALLATION. . . . . . . . . . 08-10–11 PRE-TENSIONER SEAT BELT
SAS CONTROL MODULE DISPOSAL PROCEDURES . . . . . . . . . . 08-10–30
REMOVAL/INSTALLATION. . . . . . . . . . 08-10–11 INSPECTION OF SST
SAS CONTROL MODULE (DEPLOYMENT TOOL) . . . . . . . . . . . . . 08-10–31
CONFIGURATION . . . . . . . . . . . . . . . . . 08-10–12 Inspection Procedure . . . . . . . . . . . . . . 08-10–31

End of Toc
WM: AIR BAG SYSTEM

08-10–1
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AIR BAG SYSTEM

AIR BAG SYSTEM LOCATION INDEX
id081000805300

3 1

2
4

9
10

7
5

11

5 12

ac9uuw00000685

1 Driver-side air bag module 6 Clock spring

(See 08-10-6 DRIVER-SIDE AIR BAG MODULE (See 08-10-15 CLOCK SPRING REMOVAL/
REMOVAL/INSTALLATION.) INSTALLATION.)
(See 08-10-17 AIR BAG MODULE AND PRE- (See 08-10-16 CLOCK SPRING INSPECTION.)
TENSIONER SEAT BELT DEPLOYMENT (See 08-10-15 CLOCK SPRING ADJUSTMENT.)
PROCEDURES.) 7 Crash zone sensor
2 Passenger-side air bag module (See 08-10-11 CRASH ZONE SENSOR
(See 08-10-7 PASSENGER-SIDE AIR BAG REMOVAL/INSTALLATION.)
MODULE REMOVAL/INSTALLATION.) 8 Side air bag sensor No. 1
(See .08-10-17 AIR BAG MODULE AND PRE- (See 08-10-14 SIDE AIR BAG SENSOR NO. 1
TENSIONER SEAT BELT DEPLOYMENT REMOVAL/INSTALLATION.)
PROCEDURES)
9 Side air bag sensor No. 2
3 Curtain air bag module (See 08-10-14 SIDE AIR BAG SENSOR NO. 2
(See 08-10-10 CURTAIN AIR BAG MODULE REMOVAL/INSTALLATION.)
REMOVAL/INSTALLATION.)
(See 08-10-17 AIR BAG MODULE AND PRE- 10 Side air bag module
TENSIONER SEAT BELT DEPLOYMENT (See 08-10-8 SIDE AIR BAG MODULE REMOVAL/
PROCEDURES.) INSTALLATION.)
(See 08-10-17 AIR BAG MODULE AND PRE-
4 SAS control module TENSIONER SEAT BELT DEPLOYMENT
(See 08-10-11 SAS CONTROL MODULE PROCEDURES.)
REMOVAL/INSTALLATION.)
11 Seat weight sensor control module
5 Pre-tensioner seat belt (See 08-10-12 SEAT WEIGHT SENSOR CONTROL
(See 08-10-17 AIR BAG MODULE AND PRE- MODULE REMOVAL/INSTALLATION.)
TENSIONER SEAT BELT DEPLOYMENT
PROCEDURES.)

08-10–2
1890-1U-06H(08-10).fm 3 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

12 Seat weight sensor
(See 09-13-3 FRONT SEAT DISASSEMBLY/
ASSEMBLY.)
(See 08-10-13 SEAT WEIGHT SENSOR
CALIBRATION.)
(See 08-10-13 SEAT WEIGHT SENSOR
INSPECTION.)

End Of Sie
AIR BAG SYSTEM SERVICE WARNINGS
id081000800200
Air Bag Module Inspection
• Inspecting an air bag module using a tester
can operate (deploy) the air bag module, NO GOOD
which may cause serious injury. Do not use a
tester to inspect an air bag module. Always
use the on-board diagnostic function to
diagnose the air bag module for malfunctions.

ac9uuw00000750

Air Bag Module Handling 08-10

• Before removing the air bag module or disconnecting the air bag module connector, always turn the
ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or
more to allow the backup power supply of the SAS control module to deplete its stored power.
• Handling a live (undeployed) air bag module
that is pointed toward your body could result
in serious injury if the air bag module were to
accidentally operate (deploy). When carrying
a live (undeployed) air bag module, point the
deployment surface away from your body to
lessen the chance of injury in case it operates
(deploys).

GOOD NO GOOD
ac9uuw00000751

• A live (undeployed) air bag module placed

with its deployment surface to ground is GOOD NO GOOD
dangerous. If the air bag module were to
accidentally operate (deploy), it could cause
serious injury. Always place a live
(undeployed) air bag module with its
deployment surface up.

ac9uuw00000752

Side Air Bag Module Handling

• Before removing the side air bag module or disconnecting the side air bag module connector, always
turn the ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1
min or more to allow the backup power supply of the SAS control module to deplete its stored power.
• When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad,
frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat
back that has been reused, a serious accident may result. After a side air bag has operated (deployed),
always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After
servicing, verify that the seat operates normally and that the wiring harness is not caught.

08-10–3
1890-1U-06H(08-10).fm 4 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

Seat Weight Sensor Handling
• The front passenger-side seat and the seat weight sensor may become deformed or otherwise
damaged due to operation (deployment) of the front or side air bag in an accident. This may cause the
passenger sensing function to operate improperly and result in a serious accident. Always replace the
front passenger seat and seat weight sensor with new ones after the front or side air bags have
operated (deployed). After servicing, verify that the seat operates normally and that the wiring harness
is not caught. If the collision is not hard enough to cause the front or side air bags to operate (deploy),
inspect the seat weight sensor and replace it if there is any malfunction.

SAS Control Module Handling

• Removing the SAS control module or disconnecting the SAS control module connector with the
ignition switch at the ON position can activate the sensor in the SAS control module and operate
(deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing the
SAS control module or disconnecting the SAS control module connector, always turn the ignition
switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or more to
allow the backup power supply of the SAS control module to deplete its stored power.
• Connecting the SAS control module connector with the SAS control module not securely fixed to the
vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air
bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pre-tensioner
seat belts, which may result in serious injury. Therefore, before connecting the connector, securely fix
the SAS control module to the vehicle.
• Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the SAS control module must be replaced
with a new one even if the used one does not have any visible external damage or deformation. The
used SAS control module may have been damaged internally, which may cause improper operation. If
the SAS control module is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the SAS control module with a new
one. The SAS control module cannot be bench-checked or self-checked.

Crash Zone Sensor Handling

• Removing the crash zone sensor or disconnecting the crash zone sensor connector with the ignition
switch at the ON position can activate the crash zone sensor and operate (deploy) the air bags and pre-
tensioner seat belts, which may cause serious injury. Before removing the crash zone sensor or
disconnecting the crash zone sensor connector, always turn the ignition switch to the LOCK position,
disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power
supply of the SAS control module to deplete its stored power.
• If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bags and pre-
tensioner seat belts may accidentally operate (deploy) and cause injury, or the system may fail to
operate normally and cause a serious accident. Do not subject the crash zone sensor to shock or
disassemble the sensor.
• Because a sensor is built into the crash zone sensor, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the crash zone sensor must be replaced
with a new one even if the used one does not have any visible external damage or deformation. If the
crash zone sensor is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the crash zone sensor with a new
one. The crash zone sensor cannot be bench-checked or self-checked.

Side Air Bag Sensor Handling

• Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition
switch at the ON position can activate the side air bag sensor and operate (deploy) the side air bag,
which may cause serious injury. Before removing the side air bag sensor or disconnecting the side air
bag sensor connector, always turn the ignition switch to the LOCK position, disconnect the negative
battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control
module to deplete its stored power.
• If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may
accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a
serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
• Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to
a collision or other causes, the side air bag sensor must be replaced with a new one even if the used
one does not have any visible external damage or deformation. If the side air bag sensor is reused, the
side air bag may not operate (deploy) normally, which could result in a serious accident. Always
replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-checked or
self-checked.

08-10–4
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AIR BAG SYSTEM

Pre-tensioner Seat Belt Inspection
• Inspecting a pre-tensioner seat belt using a
tester can operate (deploy) the pre-tensioner
seat belt, which may cause serious injury. Do
not use a tester to inspect a pre-tensioner
seat belt. Always use the on-board diagnostic
function to diagnose the pre-tensioner seat
belt for malfunctions.
End Of Sie

ac9uuw00000753

AIR BAG SYSTEM SERVICE CAUTIONS

id081000800300
Air Bag System Component Disassembly
• Disassembling the air bag system components could cause it to not operate (deploy) normally. Never
disassemble any air bag system components.

08-10

NO GOOD
ac9uuw00000754

Air Bag Module, Pre-tensioner Seat Belt Handling

• Oil, grease, or water on the air bag modules may cause the air bags and pre-tensioner seat belts to fail
to operate (deploy) in an accident. Never allow oil, grease, or water to get on the air bag modules or
pre-tensioner seat belts.
• Inserting a screwdriver or similar object into
the connector of an air bag module or a pre-
tensioner seat belt may damage the connector
and cause the air bag module or the pre-
tensioner seat belt to operate (deploy)
improperly, which may cause serious injury.
Never insert any foreign objects into the air
bag module or seat belt connectors.

ac9uuw00000755

Seat Weight Sensor Handling

• The seat weight sensor has a built-in strain gauge which may operate improperly if the sensor is
dropped by itself or when installed to the seat. If it is dropped, replace the seat weight sensor with a
new one.
• Oil, grease, or water on the seat weight sensor may cause the system to operate (deploy) improperly.
Never allow oil, grease, or water to get on the seat weight sensor.
• Foreign material in the seat weight sensor components may cause the system to operate (deploy)
improperly. Always make sure that no foreign material can get into the seat weight sensor.
• Disassembling the seat weight sensor, or tightening any of the nuts and bolts installed to the sensor
body may cause it to operate (deploy) improperly. Never disassemble the seat weight sensor or tighten
any of the nuts or bolts installed to the body of the sensor.

08-10–5
1890-1U-06H(08-10).fm 6 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

Air Bag Module, Pre-tensioner Seat Belt Reuse
• Even if an air bag module or a pre-tensioner seat belt does not operate (deploy) in a collision and does
not have any external signs of damage, it may have been damaged internally, which may cause
improper operation. Before reusing a live (undeployed) air bag module and the pre-tensioner seat belts,
always use the on-board diagnostic to diagnose the air bag module and the pre-tensioner seat belts to
verify that they have no malfunction.

Air Bag Wiring Harness Repair

• Incorrectly repairing an air bag wiring harness
can accidentally operate (deploy) the air bag
module and pre-tensioner seat belts. If a
problem is found in the air bag wiring
harness, always replace the wiring harness
with a new one.
End Of Sie
WM: DRIVER-SIDE AIR BAG MODULE

NO GOOD
acxuuw00001180

DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION

id081000801300

Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read the air bag system service warnings and cautions before handling the
air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG
SYSTEM SERVICE CAUTIONS.)

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove in the order indicated in the table.
3
1 Cover 5
2 Bolt
3 Connector A
(See 08-10-6 Connector A Removal Note.)
4 Connector B
5 Driver-side air bag module 1
2 1
4. Install in the reverse order of removal. 2 4 9—12
5. Turn the ignition switch to the ON position. 9—12 {90—130, 78—113}
{90—130, 78—113} N·m {kgf·cm, in·lbf}
6. Verify that the air bag system warning light
ac9uuw00000451
illuminates for approx. 6 s and goes out.
• If the air bag system warning light does not
operate normally, refer to the on-board diagnostic system (air bag system) and perform inspection of the
system. (See 08-02-2 FLOWCHART.)

Connector A Removal Note

1. Using a flathead screwdriver, pry out the
connector stopper plate.
2. Disconnect the connector.
End Of Sie
WM: PASSENGER-SIDE AIR BAG MODULE

STOPPER
PLATE

acxuuw00000638

08-10–6
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AIR BAG SYSTEM

PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION
id081000801900

Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read the air bag system service warnings and cautions before handling the
air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG
SYSTEM SERVICE CAUTIONS.)
• Due to the adoption of 2-step deployment control in the passenger-side air bag module,
depending on the impact force, it is possible that inflator No.2 might not deploy. In such cases,
before disposing of the air bag module, make sure to follow the inflator deployment procedures
and verify complete deployment of inflators No.1 and 2.

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove the following parts:
(1) Decoration panel (See 09-17-23 DECORATION PANEL REMOVAL/INSTALLATION.)
(2) Front console box mat (See 09-17-15 FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
(3) Indicator panel (See 09-17-15 INDICATOR PANEL REMOVAL/INSTALLATION.)
(4) Front console box (See 09-17-16 FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
(5) Center panel (See 09-17-10 CENTER PANEL REMOVAL/INSTALLATION.)
(6) Front scuff plate inner (RH) (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(7) Front side trim (RH) (See 09-17-23 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(8) Dashboard under cover (Passenger side) (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
(9) Glove compartment (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
(10)Side panel (See 09-17-13 SIDE PANEL REMOVAL/INSTALLATION.) 08-10
(11)Dashboard garnish (See 09-17-22 DASHBOARD GARNISH REMOVAL/INSTALLATION.)
(12)HF/TEL unit (See 09-20-25 HANDS-FREE TELEPHONE (HF/TEL) UNIT REMOVAL/INSTALLATION.)
(vehicles with HF/TEL system)
4. Remove the bolts. CLIP
5. Remove the screws. PASSENGER-SIDE CLIP A
AIR BAG MODULE
6. Remove the clips.
7. Remove the connector.
CONNECTOR
8. Remove the passenger-side air bag module in the
direction of the arrow A
9. Install in the reverse order of removal. A
10. Turn the ignition switch to the ON position. A
A
11. Verify that the air bag system warning light
illuminates for approx. 6 s and goes out.
• If the air bag system warning light does not
operate normally, refer to the on-board
diagnostic system (air bag system) and
SCREW
perform inspection of the system. (See 08-02-
2 FLOWCHART.)
End Of Sie
WM: SIDE AIR BAG MODULE

BOLT
7.8—10.8 N·m
{79.6—110.1 kgf·cm,
69.1—95.5 in·lbf}

ac9uuw00000817

08-10–7
1890-1U-06H(08-10).fm 8 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

SIDE AIR BAG MODULE REMOVAL/INSTALLATION
id081000800800

Warning
• Handling the air bag module improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the air bag system service warnings and cautions before
handling the air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5
AIR BAG SYSTEM SERVICE CAUTIONS.)
• If the side air bag module is installed with debris in the seat back, the foreign material may be
scattered when the side air bag module operates (deploys), causing injury. Verify that there is no
foreign material in the seat back before installing the side air bag module.

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.
3. Slide hook A upward and remove it from hook B. HOOK F
4. Open the fastener. HOOK E
HOOK D

HOOK C

FRONT HOOK A

FASTENER
HOOK B

ac9uuw00002324

5. Insert a flathead screwdriver between hook C and

the frame.
6. Pull the flathead screwdriver in the direction of the
arrow as shown in the figure.
7. Remove the hook C.
8. Remove the hook D.
9. Remove the hook E. HOOK C,E

FLATHEAD
SCREWDRIVER

HOOK C, E
FRONT FRAME

FLATHEAD
SCREWDRIVER

ac9uuw00002325

08-10–8
1890-1U-06H(08-10).fm 9 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

10. Remove the hook F. HOOK F HOOK F
11. Partially peel back the seat back trim.

ac9uuw00002412

12. Remove in the nuts.

13. Partially peel back the seat back pad.
14. Remove the side air bag module.
CONNECTOR

NUT
4.5—8.0 N·m
{46—81 kgf·cm,
40—70 in·lbf}

SIDE AIR BAG

MODULE 08-10

ac9uuw00001676

15. Using a flathead screwdriver, pry out the

connector stopper plate.
16. Disconnect the connector.
17. Install in the reverse order of removal.
18. Turn the ignition switch to the ON position.
19. Verify that the air bag system warning light
illuminates for approx. 6 s and goes out. STOPPER
• If the air bag system warning light does not PLATE
operate normally, refer to the on-board
diagnostic system (air bag system) and
perform inspection of the system. (See 08-02-
2 FLOWCHART.)
acxuuw00000638
End Of Sie
WM: CURTAIN AIR BAG MODULE

08-10–9
1890-1U-06H(08-10).fm 10 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

CURTAIN AIR BAG MODULE REMOVAL/INSTALLATION
id081000800900

Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read the air bag system service warnings and cautions before handling the
air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG
SYSTEM SERVICE CAUTIONS.)
1. Turn the ignition switch to the LOCK position.
2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove the following parts:
(1) A-pillar trim (See 09-17-19 A-PILLAR TRIM REMOVAL/INSTALLATION.)
(2) Front scuff plate inner (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(3) Rear scuff plate inner (See 09-17-24 REAR SCUFF PLATE REMOVAL/INSTALLATION.)
(4) Front seat belt lower anchor installation bolt (Driver side) (See 08-11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
(5) B-pillar lower trim (See 09-17-20 B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
(6) Front seat belt upper anchor installation bolt (See 08-11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
(7) B-pillar upper trim (See 09-17-20 B-PILLAR UPPER TRIM REMOVAL/INSTALLATION.)
(8) Trunk box (See 09-17-29 TRUNK BOX REMOVAL/INSTALLATION.)
(9) Seat side box (See 09-17-29 SEAT SIDE BOX REMOVAL/INSTALLATION.)
(10)Trunk end trim (See 09-17-28 TRUNK END TRIM REMOVAL/INSTALLATION.)
(11)Third-row seat (See 09-13-22 THIRD-ROW SEAT REMOVAL/INSTALLATION.)
(12)Third-row seat belt lower anchor installation bolt (See 08-11-5 THIRD-ROW SEAT BELT REMOVAL/
INSTALLATION.)
(13)Trunk side trim (See 09-17-27 TRUNK SIDE TRIM REMOVAL/INSTALLATION)
(14)Roof side trim (See 09-17-21 ROOF SIDE TRIM REMOVAL/INSTALLATION.)
(15)Second-row seat belt upper anchor installation bolt (See 08-11-4 SECOND-ROW SEAT BELT REMOVAL/
INSTALLATION.)
(16)C-pillar trim (See 09-17-21 C-PILLAR TRIM REMOVAL/INSTALLATION.)
(17)Third-row seat belt upper anchor installation bolt (See 08-11-5 THIRD-ROW SEAT BELT REMOVAL/
INSTALLATION.)
(18)D-pillar trim (See 09-17-22 D-PILLAR TRIM REMOVAL/INSTALLATION.)
(19)Front map light (See 09-18-29 FRONT MAP LIGHT REMOVAL/INSTALLATION.)
(20)Sunvisor (See 09-17-31 SUNVISOR REMOVAL/INSTALLATION.)
(21)Assist handle (See 09-17-31 ASSIST HANDLE REMOVAL/INSTALLATION.)
(22)RES unit cover (Vehicles with RES) (See 09-20-22 RES UNIT REMOVAL/INSTALLATION.)
(23)Headliner (See 09-17-32 HEADLINER REMOVAL/INSTALLATION.)
(24)Rear speaker (See 09-20-12 REAR SPEAKER REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.

7 7
3
3 6

3
3 3 3 1 6
4
4

2
7.8—10.8
5
2 {79.6—110.1,
7.8—10.8
2
7.8—10.8 69.1—95.5} 7.8—10.8
{79.6—110.1,
{79.6—110.1, 69.1—95.5} {79.6—110.1,
69.1—95.5} 69.1—95.5}
N·m {kgf·cm, in·lbf}

ac9uuw00000574

1 Connector 5 Bolt B
2 Bolt 6 Hook B
3 Hook A 7 Hook C
4 Clip 8 Curtain air bag module

08-10–10
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AIR BAG SYSTEM

5. Install in the reverse order of removal.

Caution
• After installing the curtain air bags, verify that the connector and wiring harness are not caught.

6. When the ignition switch is turned to the ON position verify that the air bag system warning light illuminates for
approx. 6 s and goes out.
• If the air bag system warning light does not operate normally, refer to the on-board diagnostic system (air
bag system) and perform inspection of the system. (See 08-02-2 FLOWCHART.)
End Of Sie
CRASH ZONE SENSOR REMOVAL/INSTALLATION
WM: CRASH ZONE SENSOR

id081000800500

Warning
• Handling the crash zone sensor improperly can accidentally deploy the air bags and pre-tensioner
seat belts, which may seriously injure you. Read the air bag system service warnings and cautions
before handling the crash zone sensor. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM SERVICE CAUTIONS.)

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove the front bumper. (See 09-10-3 FRONT BUMPER REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
FRONT
1 Bolt A
2 Cover
2
3 Bolt B 5 08-10
4 Connector 1
5 Crash zone sensor 4
3 7.8—10.8
5. Install in the reverse order of removal. {79.6—110.1,
69.1—95.5}
6. Turn the ignition switch to the ON position.
7. Verify that the air bag system warning light
N·m {kgf·cm, in·lbf}
illuminates for approx. 6 s and goes out.
• If the air bag system warning light does not
ac9uuw00000597

operate normally, refer to the on-board

diagnostic system (air bag system) and perform inspection of the system. (See 08-02-2 FLOWCHART.)
End Of Sie
SAS CONTROL MODULE REMOVAL/INSTALLATION
WM: SAS UNIT

id081000801400

Warning
• Handling the SAS control module improperly can accidentally deploy the air bag modules and pre-
tensioner seat belt, which may seriously injure you. Read the service warnings and cautions
before handling the air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See
08-10-5 AIR BAG SYSTEM SERVICE CAUTIONS.)
• Connecting the SAS control module with the SAS control module not securely fixed to the vehicle
is dangerous. When the ignition switch is turned to the ON position, the SAS control module could
tilt causing the SAS control module to detect that the vehicle is in a rollover condition, which may
accidentally operate (deploy) the curtain air bag module and pre-tensioner seat belt. Therefore,
before turning the ignition switch to the ON position with the connector connected, securely fix
the SAS control module to the vehicle.
Caution
• Handling the SAS control module improperly can accidentally deploy the air bag modules and pre-
tensioner seat belt, which may seriously injure you. If configuration is not completed before
removing the SAS control module, DTC B2477 will be displayed.
1. Perform SAS control module configuration when replacing it. (See 08-10-12 SAS CONTROL MODULE
CONFIGURATION.)
2. Turn the ignition switch to the LOCK position.
3. Disconnect the negative battery cable and wait for 1 min or more.
4. Remove the following parts:
(1) Dashboard under cover (Passenger side) (See 09-17-14 DASHBOARD UNDER COVER REMOVAL/
INSTALLATION.)
(2) Side wall (See 09-17-14 SIDE WALL REMOVAL/INSTALLATION.)
(3) Console panel (Passenger side) (See 09-17-18 CONSOLE PANEL REMOVAL/INSTALLATION.)

08-10–11
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AIR BAG SYSTEM

5. Remove the connector.
6. Remove the nuts.
7. Remove the SAS control module in the direction
7.8—10.8
of the arrow BOLT {79.6—110.1,
8. Install in the reverse order of removal. 69.1—95.5}
9. Turn the ignition switch to the ON position.
• If the SAS control module is replaced, turn the
ignition switch to the ON position for 20 s or
more after completing the configuration.
SAS CONTROL
10. Verify that the air bag system warning light MODULE
illuminates for approx. 6 s and goes out.
• If the air bag system warning light does not CONNECTOR
operate, refer to the on-board diagnostic
system (air bag system) and perform
inspection of the system. (See 08-02-2
FLOWCHART.)
N·m {kgf·cm, in·lbf}
End Of Sie
ac9uuw00000764

SAS CONTROL MODULE CONFIGURATION

id081000801500
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Module Programming”.
• When using the PDS (Pocket PC)
1. Select “Programming”.
2. Select “Module Programming”. DLC-2
3. Then, select items from the screen menu in the
following order.
1. Select “Programmable Module Installation”.
ac9uuw00000452
2. Select “RCM”.
4. Configuration is performed in accordance with the
screen instructions.
5. Retrieve DTCs using the M-MDS and verify that there is no DTC present.
• If any DTC is present, perform applicable DTC inspection. (See 08-02-4 DTC TABLE.)
End Of Sie
SEAT WEIGHT SENSOR CONTROL MODULE REMOVAL/INSTALLATION
id081000801600

Caution
• When the seat weight sensor control module is replaced with a new one, perform the seat weight
sensor calibration using the M-MDS. (See 08-10-13 SEAT WEIGHT SENSOR CALIBRATION.)

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove the front passenger seat. (See 09-13-3 FRONT SEAT REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
1 Connector
2 Fastener
3 Seat weight sensor control module

5. Install in the reverse order of removal.

End Of Sie 1

3
2
ac9uuw00000763

08-10–12
1890-1U-06H(08-10).fm 13 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

SEAT WEIGHT SENSOR CALIBRATION
id081000801700

Caution
• If any of the following work is performed, perform the seat weight sensor calibration using the M-
MDS.
— Replacement with a new seat weight sensor
— Replacement with a new seat weight sensor control module
— Replacement with new front passenger-side seat parts
— Disassembly of the front passenger-side seat
• If any of the following work is performed or when the vehicle has been involved in a collision,
perform the seat weight sensor inspection using the M-MDS. (See 08-10-13 SEAT WEIGHT
SENSOR INSPECTION.)
— Removal of the front passenger-side seat
— Loosening and retightening of front passenger-seat fixing bolts

1. Have two 20 kg {44 lb} weights ready to use.

2. Connect the M-MDS to the DLC-2 connector.
3. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Body”.
3. Select “Restraints”.
• When using the PDS (Pocket PC)
1. Select “All Tests and Calibrations”. DLC-2
4. Then, select item from the screen menu in the 08-10
following order.
1. Select “Passenger Seat Weight Sensor
ac9uuw00000761
ReZero”.
5. Perform calibration following the procedures on
the M-MDS screen.
End Of Sie
SEAT WEIGHT SENSOR INSPECTION
id081000801800

Caution
• If any of the following work is performed or when the vehicle has been involved in a collision,
perform the seat weight sensor inspection using the M-MDS.
— Removal of the front passenger-side seat
— Loosening and retightening of front passenger-seat fixing bolts
• If any of the following work is performed, perform the seat weight sensor calibration using the M-
MDS. (See 08-10-13 SEAT WEIGHT SENSOR CALIBRATION.)
— Replacement with a new seat weight sensor
— Replacement with a new seat weight sensor control module
— Replacement with new front passenger-side seat parts
— Disassembly of the front passenger-side seat

1. Connect the M-MDS to the DLC-2 connector.

2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (laptop PC)
1. Select the “Toolbox” tab.
2. Select “Body”.
3. Select “Restraints”.
• When using the PDS (Pocket PC)
1. Select “All Tests and Calibrations”. DLC-2
3. Then, select item from the screen menu in the
following order.
1. Select “Passenger Seat Weight Sensor
ac9uuw00000760
ReZero”.
4. Perform inspection following the procedures on
the M-MDS screen.
End Of Sie
WM: SIDE AIR BAG SENSOR

08-10–13
1890-1U-06H(08-10).fm 14 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

SIDE AIR BAG SENSOR NO. 1 REMOVAL/INSTALLATION
id081000800600

Warning
• Handling the side air bag sensor improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the air bag system service warnings and cautions before
handling the side air bag sensor. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-
10-5 AIR BAG SYSTEM SERVICE CAUTIONS.)

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove the following parts:
(1) Front scuff plate inner (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(2) Rear scuff plate inner (See 09-17-24 REAR SCUFF PLATE REMOVAL/INSTALLATION.)
(3) Front seat belt lower anchor installation bolt (Driver side) (See 08-11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
(4) B-pillar lower trim (See 09-17-20 B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
1 Nut
2 Connector
3 Side air bag sensor No. 1
3
5. Install in the reverse order of removal. FRONT
6. Turn the ignition switch to the ON position and
hold for 10 s or more. 7.8—10.8
1 {79.6—110.1,69.1—95.5 }
7. Verify that the air bag system warning light
2
illuminates for approx. 6 s and goes out.
• If the air bag system warning light does not N·m {kgf·cm, in·lbf}

operate normally, refer to the on-board ac9uuw00000393

diagnostic system (air bag system) and

perform inspection of the system. (See 08-02-2 FLOWCHART.)
End Of Sie
SIDE AIR BAG SENSOR NO. 2 REMOVAL/INSTALLATION
id081000800700

Warning
• Handling the side air bag sensor improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the air bag system service warnings and cautions before
handling the side air bag sensor. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-
10-5 AIR BAG SYSTEM SERVICE CAUTIONS.)
1. Turn the ignition switch to the LOCK position.
2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove the following parts:
(1) Trunk box (See 09-17-29 TRUNK BOX REMOVAL/INSTALLATION.)
(2) Seat side box (See 09-17-29 SEAT SIDE BOX REMOVAL/INSTALLATION.)
(3) Trunk end trim (See 09-17-28 TRUNK END TRIM REMOVAL/INSTALLATION.)
(4) Third-row seat (See 09-13-22 THIRD-ROW SEAT REMOVAL/INSTALLATION.)
(5) Third-row seat belt lower anchor installation bolt (See 08-11-5 THIRD-ROW SEAT BELT REMOVAL/
INSTALLATION.)
(6) Trunk side trim (See 09-17-27 TRUNK SIDE TRIM REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
1 Nut
2 Side air bag sensor No. 2
3 Connector

5. Install in the reverse order of removal. 2

FRONT
6. Turn the ignition switch to the ON position and
hold for 10 s or more. 1
7. Verify that the air bag system warning light 7.8—10.8
illuminates for approx. 6 s and goes out. {79.6—110.1, 3
• If the air bag system warning light does not 69.1—95.5} N·m {kgf·cm, in·lbf}
operate normally, refer to the on-board ac9uuw00000394

diagnostic system (air bag system) and

perform inspection of the system. (See 08-02-2 FLOWCHART.)
End Of Sie
WM: CLOCK SPRING

08-10–14
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AIR BAG SYSTEM

CLOCK SPRING REMOVAL/INSTALLATION
id081000802000
1. Disconnect the negative battery cable and wait for 1 min or more.
2. Remove the following parts:
(1) Driver-side air bag module (See 08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
(2) Steering wheel (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(3) Column cover (See 09-17-8 COLUMN COVER REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
1 Connector
2 Screw
3 Clock spring 3
2
4. Install in the reverse order of removal.
5. Turn the ignition switch to the ON position. 1
6. Verify that the air bag system warning light
illuminates for approx. 6 s and goes out.
• If the air bag system warning light does not
operate normally, refer to the on-board
diagnostic system (air bag system) and ac9uuw00000762

perform inspection of the system. (See 08-02-

2 FLOWCHART.)
End Of Sie
CLOCK SPRING ADJUSTMENT
id081000802100

Note
• The adjustment procedure is also specified on the caution label of the clock spring. 08-10

1. Set the front tires straight-ahead.

Caution
• The clock spring will break if over-wound. Do not forcibly turn the clock spring.

2. Turn the clock spring clockwise until it stops.

acxuuw00001596

3. From the stopped position, turn the clock spring

counterclockwise 2 3/4 turns.

acxuuw00001597

08-10–15
1890-1U-06H(08-10).fm 16 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

4. Align the marks.
End Of Sie ALIGNMENT MARKS

acxuuw00001598
CLOCK SPRING INSPECTION
id081000802200
1. Verify that the continuity is as indicated in the table.
• If not as indicated in the table, replace the clock spring.
Note
• When the vehicle-side connector for the clock spring is disconnected, terminals 1A, 1B, 1C and 1D are
shorted to prevent unexpected operation (deployment) of the air bag module.

: Continuity
Test Terminal
condi-
tion 1A 1B 1C 1D 2A 2B 2C 2D 2E 2F 2G 2H 3A 3B 4A 4B 5A 5B 5C 5D 5E 5F 5G 5H

Under
any
condi-
tion

ac9uuw00000829

3B 3A 4B 4A 5A 5B 5C 5D 5E 5F 5G 5H

HANDS-
A/B A/B A/B A/B CRUISE CRUISE ILLUMI- ILLUMI- FREE AUDIO AUDIO
No.1 No.1 No.2 No.2 HORN
CONTROL CONTROL NATION NATION TELEPHONE CONTROL CONTROL
+ - + - + - + - + -
SWITCH

1C 1D 1A 1B 2A 2B 2C 2D 2E 2F 2G 2H

VEHICLE-SIDE CONNECTOR

1D 1C 1B 1A 2H 2G 2F 2E 2D 2C 2B 2A

AIR BAG MODULE-SIDE CONNECTOR

3B 3A 4B 4A
5H 5G 5F 5E 5D 5C 5B 5A

ac9uuw00000830
End Of Sie

08-10–16
1890-1U-06H(08-10).fm 17 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT PROCEDURES
WM: AIR BAG MODULES

id081000801100

Warning
• A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy)
when it is disposed of and cause serious injury. Do not dispose of a live (undeployed) air bag
module and pre-tensioner seat belt. If the SSTs (Deployment tool and Adapter harness) are not
available, consult the nearest Mazda representative for assistance.
Caution
• Deploying the air bag modules and pre-tensioner seat belts inside the vehicle may cause damage
to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules
and pre-tensioner seat belts outside the vehicle.

• If the vehicle is to be scrapped, or when disposing of any air bag modules or pre-tensioner seat belts, operate
(deploy) them inside the vehicle by following the deployment procedure below and using the SST (Deployment
tool).
• When disposing of an operated (deployed) air bag module and pre-tensioner seat belt, refer to “AIR BAG
MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES”.

Deployment Procedure for Inside of Vehicle

1. Inspect the SST (Deployment tool). (See 08-10-31 INSPECTION OF SST (DEPLOYMENT TOOL).)
2. Move the vehicle to an open space, away from strong winds, and close all of the vehicle doors and windows.
3. Turn the ignition switch to the LOCK position.
4. Disconnect the negative battery cable and wait for 1 min or more.
5. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.
08-10
Driver-side Air Bag Module
Warning
• The driver-side air bag module is a dual inflator type. If one inflator is forced to operate (deploy),
the other may operate (deploy) accidentally. To prevent injury while disposing of the air bag
module, make sure to operate (deploy) both driver-side air bag module inflators simultaneously,
following the procedure below.
Note
• The SSTs, two types of adopter harnesses (for inflators No.1 and No.2) and two deployment tools are to
be used to operate (deploy) the driver-side air bag module.
1. Remove the driver-side air bag module.
(See 08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
2. Connect the SSTs (Adapter harness) to the
driver-side air bag module as shown in the figure.
3. Install the driver-side air bag module. 49 G066 003
(See 08-10-6 DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)

49 L066 002
ac9uuw00000756
4. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

49 G066 003 49 L066 002

49 H066 002 49 H066 002

acxuuw00001266

08-10–17
1890-1U-06H(08-10).fm 18 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

5. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery
terminal, and the black clip to the negative battery terminal.
6. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.
7. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.
8. Press the activation switch on the SST
(Deployment tool) connected with 49 L066 002
49 H066 002
(a yellow connector) of the SST (Adapter
ACTIVATION
harness), and after 3 s, press the activation SWITCH
switch on the other SST (Deployment tool) to
operate (deploy) the air bag module (both
inflators).
Warning
• Verify that air bag module operation
(explosive) sound occurs twice. If no
operation (explosive) sound was heard or
a single operation (explosive) sound was acxuuw00001267
heard, both inflators would not have
operated (deployed) properly. This may
cause serious injury if the air bag module operates (deploy) unexpectedly. If the two operation
(explosive) sounds are not heard, perform Step 8 again. If a total of two operation (explosive)
sounds cannot be verified even though Step 8 is performed again, leave the air bag module alone
for 30 min or more before approaching it again.
• The air bag module is very hot immediately after it is operated (deployed). You can get burned. Do
not touch the air bag module for at least 15 min after deployment.
9. Disconnect the SSTs (Deployment tool) form the SSTs (Adapter harness).
Passenger-side Air Bag Module
Warning
• The passenger-side air bag module is a dual inflator type. If one inflator is forced to operate
(deploy), the other may operate (deploy) accidentally. To prevent injury while disposing of the air
bag module, make sure to operate (deploy) both passenger-side air bag module inflators
simultaneously, following the procedure below.
Note
• The SSTs, two types of adapter harnesses (for inflators No.1 and No.2) and two deployment tools are to
be used to operate (deploy) the passenger-side air bag module.
1. Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
2. Disconnect the passenger-side air bag module connector.
3. Connect the SSTs (Adapter harness) to the
passenger-side air bag module as shown in the PASSENGER-SIDE PASSENGER-SIDE
figure. AIR BAG MODULE AIR BAG MODULE
CONNECTOR CONNECTOR

49 G066 003

49 L066 002
ac9uuw00000757
4. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness).

49 G066 003 49 L066 002

49 H066 002 49 H066 002

acxuuw00001266

08-10–18
1890-1U-06H(08-10).fm 19 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

5. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive battery
terminal, and the black clip to the negative battery terminal.
6. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.
7. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.
8. Press the activation switch on the SST
(Deployment tool) connected with 49 L066 002
49 H066 002
(a yellow connector) of the SST (Adapter
ACTIVATION
harness), and after 3 s, press the activation
SWITCH
switch on the other SST (Deployment tool) to
operate (deploy) the air bag module (both
inflators).
Warning
• Verify that air bag module operation
(explosive) sound occurs twice. If no
operation (explosive) sound was heard or
a single operation (explosive) sound was
acxuuw00001267
heard, both inflators would not have
operated (deployed) properly. This may
cause serious injury if the air bag module operates (deploy) unexpectedly. If the two operation
(explosive) sounds are not heard, perform Step 8 again. If a total of two operation (explosive)
sounds cannot be verified even though Step 8 is performed again, leave the air bag module alone
for 30 min or more before approaching it again.
• The air bag module is very hot immediately after it is operated (deployed). You can be burned. Do
not touch the air bag module for at least 15 min after deployment.
9. Disconnect the SSTs (Deployment tool) form the SSTs (Adapter harness).
Side Air Bag Module 08-10
1. Disconnect the front seat connector.
2. Connect the SST (Adapter harness) to the side
air bag module and pre-tensioner seat belt
connector as shown in the figure.

FRONT SEAT
CONNECTOR

49 B066 004
acxuuw00001269
3. Connect the SST (Deployment tool) to the SST
(Adapter harness).
4. Connect the SST (Deployment tool) to the 49 B066 004
battery. Connect the power supply red clip to the
positive battery terminal, and the black clip to the
negative battery terminal.
5. Verify that the red lamp on the SST (Deployment
tool) is illuminated.
6. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle.
49 H066 002
acxuuw00001270
7. Press the activation switch on the SST
(Deployment tool) to operate (deploy) the side
49 H066 002
air bag module.
ACTIVATION
8. Disconnect the SSTs (Deployment tool) from the SWITCH
SSTs (Adapter harness).

acxuuw00001267

08-10–19
1890-1U-06H(08-10).fm 20 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

Curtain Air Bag Module
1. Remove the C-pillar trim.
(See 09-17-21 C-PILLAR TRIM REMOVAL/INSTALLATION.)
2. Remove the D-pillar trim.
(See 09-17-22 D-PILLAR TRIM REMOVAL/INSTALLATION.)
3. Disconnect the curtain air bag module connector.
4. Connect the SST (Adapter harness) to the
CURTAIN AIR BAG
curtain air bag module as shown in the figure. 49 D066 002 CONNECTOR

ac9uuw00001912

5. Connect the SST (Deployment tool) to the SST

(Adapter harness).
6. Connect the SST (Deployment tool) to the 49 L066 002
battery. Connect the power supply red clip to the
positive battery terminal, and the black clip to the
negative battery terminal.
7. Verify that the red lamp on the SST (Deployment
tool) is illuminated.
8. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle.
49 H066 002
acxuuw00001272

9. Press the activation switch on the SST

(Deployment tool) to operate (deploy) the curtain
49 H066 002
air bag module.
ACTIVATION
10. Disconnect the SSTs (Deployment tool) from the SWITCH
SSTs (Adapter harness).

acxuuw00001267

Pre-tensioner Seat Belt

1. Remove the B-pillar lower trim.
(See 09-17-20 B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
2. Remove the pre-tensioner seat belt and connect
the SST (Adapter harness) as shown in the
figure. (See 08-11-2 FRONT SEAT BELT
REMOVAL/INSTALLATION.)
3. Install the pre-tensioner seat belt.
49 L066 002

ac9uuw00000758

08-10–20
1890-1U-06H(08-10).fm 21 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

4. Connect the SST (Deployment tool) to the SST
(Adapter harness).
5. Connect the SST (Deployment tool) to the 49 L066 002
battery. Connect the power supply red clip to the
positive battery terminal, and the black clip to the
negative battery terminal.
6. Verify that the red lamp on the SST (Deployment
tool) is illuminated.
7. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle.
49 H066 002
acxuuw00001272

8. Press the activation switch on the SST

(Deployment tool) to operate (deploy) the pre-
49 H066 002
tensioner seat belt.
ACTIVATION
9. Disconnect the SSTs (Deployment tool) from the SWITCH
SSTs (Adapter harness).

acxuuw00001267
08-10
Deployment Procedure for Outside of Vehicle
1. Inspect the SST (Deployment tool).
(See 08-10-31 INSPECTION OF SST (DEPLOYMENT TOOL).)
2. Turn the ignition switch to the LOCK position.
3. Disconnect the negative battery cable and wait for 1 min or more.
4. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.

Driver-side Air Bag Module

Warning
• The driver-side air bag module is a dual inflator type. If one inflator is forced to operate (deploy),
the other may operate (deploy) accidentally. To prevent injury while disposing of the air bag
module, make sure to operate (deploy) both driver-side air bag module inflators simultaneously,
following the procedure below.

1. Remove the driver-side air bag module.

(See 08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
2. Connect the SSTs (Adapter harness) to the
driver-side air bag module as shown in the figure.
49 G066 003

49 L066 002
ac9uuw00000756

08-10–21
1890-1U-06H(08-10).fm 22 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

3. Place the driver-side air bag module on the center
of the tire wheel with the padded surface facing DRIVER-SIDE AIR BAG MODULE
up. To secure the air bag module to the tire wheel,
wrap a wire (cross section 1.25 mm2 {0.002 in2}
WIRE
or more) through the wheel and the bolt
installation holes of the air bag module at least 4
times.

Warning
• If the air bag module is not properly
installed to the tire wheel, serious injury
may occur when the module is operated ac9uuw00000759
(deployed). When installing the air bag
module to the tire wheel, make sure the
padded surface is facing up.

4. Stack three tires without wheels on top of the tire

with the driver-side air bag module, and then TIRE WITH
stack another tire with a wheel on the very top. WHEEL

TIRE
WITHOUT
WHEEL

TIRE WITH
DRIVER-SIDE
AIR BAG
MODULE
acxuuw00001275

5. Secure the tires with wire.

acxuuw00001276

6. Connect the SSTs (Deployment tool) to the

SSTs (Adapter harness).
7. Connect both SSTs (Deployment tool) to the
battery. Connect the power supply red clip to the
positive battery terminal, and the black clip to the 49 G066 003
negative battery terminal.
8. Verify that the red lamp on both SSTs 49 H066 002
(Deployment tool) is illuminated.
9. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle.
49 H066 002
49 L066 002
acxuuw00001277

08-10–22
1890-1U-06H(08-10).fm 23 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

10. Press the activation switch on the SST
(Deployment tool) connected with 49 L066 002
49 H066 002
(a yellow connector) of the SST (Adapter
ACTIVATION
harness), and after 3 s, press the activation SWITCH
switch on other SST (Deployment tool) to
operate (deploy) the air bag module (both
inflators).

Warning
• Verify that air bag module operation
(explosive) sound occurs twice. If no
operation (explosive) sound was heard or
acxuuw00001267
a single operation (explosive) sound was
heard, both inflators would not have
operated (deployed) properly. This may cause serious injury if the air bag module operates
(deploy) unexpectedly. If the two operation (explosive) sounds are not heard, perform Step 8 again.
If a total of two operation (explosive) sounds cannot be verified even though Step 8 is performed
again, leave the air bag module alone for 30 min or more before approaching it again.
• The air bag module is very hot immediately after it is operated (deployed). You can be burned. Do
not touch the air bag module for at least 15 min after deployment.

11. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

Passenger-side Air Bag Module

Warning 08-10
• The passenger-side air bag module is a dual inflator type. If one inflator is forced to operate
(deploy), the other may operate (deploy) accidentally. To prevent injury while disposing of the air
bag module, make sure to operate (deploy) both passenger-side air bag module inflators
simultaneously, following the procedure below.

1. Remove the passenger-side air bag module.

(See 08-10-7 PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
2. Install the bolts to the passenger-side air bag
module.

PASSENGER-SIDE
AIR BAG MODULE

BOLT
acxuuw00001710

3. Connect the SSTs (Adapter harness) to the PASSENGER-SIDE

passenger-side air bag module as shown in the AIR BAG MODULE
figure.

49 G066 003 49 L066 002

ac9uuw00000818

08-10–23
1890-1U-06H(08-10).fm 24 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

4. Place the padded surface of the passenger-side
air bag module facing the center of the tire as
shown in the figure. To secure the air bag module
TIRE
to the tire wheel, wrap a wire (cross section 1.25
mm2 {0.002 in2} or more) through the tire and WIRE
around the bolts at least 4 times as shown in the
figure.

Warning
• If the air bag module is not properly PASSENGER-SIDE
secured to the tire, the tires may fall over AIR BAG MODULE
by the impact of operation (deployment) acxuuw00001712
and cause serious injury. To prevent this,
secure the air bag module properly with
the padded surface facing the center of the tire.

5. Stack the tire with the passenger-side air bag

module on top of two tires without wheels. Stack a TIRE WITH
tire without a wheel on top of the tire with the WHEEL
passenger-side air bag module, and then stack
another tire with a wheel on the very top.

TIRE
WITHOUT
TIRE WITH WHEEL
PASSENGER-SIDE
AIR BAG MODULE

acxuuw00001280

6. Secure the tires with wire.

acxuuw00001276

7. Connect the SSTs (Deployment tool) to the

SSTs (Adapter harness).
8. Connect both SSTs (Deployment tool) to the 49 L066 002
battery. Connect the power supply red clip to the 49 H066 002
positive battery terminal, and the black clip to the
negative battery terminal.
9. Verify that the red lamp on both SSTs
(Deployment tool) is illuminated. 49 H066 002
10. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle. 49 G066 003

acxuuw00001281

08-10–24
1890-1U-06H(08-10).fm 25 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

11. Press the activation switch on the SST
(Deployment tool) connected with 46 L066 002
49 H066 002
(a yellow connector) of the SST (Adapter
ACTIVATION
harness), and after 3 s, press the activation SWITCH
switch on the other SST (Deployment tool) to
operate (deploy) the air bag module (both
inflators).

Warning
• Verify that air bag module operation
(explosive) sound occurs twice. If no
operation (explosive) sound was heard or
acxuuw00001267
a single operation (explosive) sound was
heard, both inflators would not have
operated (deployed) properly. This may cause serious injury if the air bag module operates
(deploy) unexpectedly. If the two operation (explosive) sounds are not heard, perform Step 8 again.
If a total of two operation (explosive) sounds cannot be verified even though Step 8 is performed
again, leave the air bag module alone for 30 min or more before approaching it again.
• The air bag module is very hot immediately after it is operated (deployed). You can be burned. Do
not touch the air bag module for at least 15 min after deployment.

12. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness).

Side Air Bag Module

1. Remove the side air bag module.
(See 08-10-8 SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 08-10
2. Install the nuts to the side air bag module as NUT
shown in the figure, and connect the SST
(Adapter harness).

SIDE AIR BAG

MODULE

49 L066 002

acxuuw00001282

3. Place the padded surface of the side air bag

module facing the center of the tire as shown in WIRE
the figure. To secure the air bag module to the tire
WIRE
wheel, wrap a wire (cross section 1.25 mm2
{0.002 in2} or more) through the tire and around TIRE
the bolts at least 4 times.

Warning SIDE AIR BAG

• If the air bag module is not properly MODULE
secured to the tire, the tires may fall over
by the impact of operation (deployment)
and cause serious injury. To prevent this, acxuuw00001283
secure the air bag module properly with
the padded surface facing the center of the tire.

08-10–25
1890-1U-06H(08-10).fm 26 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

4. Stack the tire with the side air bag module on top
of two tires without wheels. Stack a tire without a TIRE WITH
wheel on top of the tire with the side air bag WHEEL
module, and then stack another tire with a wheel
on the very top.
TIRE WITH TIRE
SIDE AIR BAG WITHOUT
MODULE WHEEL

acxuuw00001284

5. Secure the tires with wire.

acxuuw00001276

6. Connect the SST (Deployment tool) to the SST

(Adapter harness).
7. Connect the SST (Deployment tool) to the
battery. Connect the power supply red clip to the 49 L066 002
positive battery terminal, and the black clip to the
negative battery terminal.
8. Verify that the red lamp on the SST (Deployment
tool) is illuminated.
49 H066 002
9. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle.

acxuuw00001285

10. Press the activation switch on the SST

(Deployment tool) to operate (deploy) the side
49 H066 002
air bag module.
ACTIVATION
11. Disconnect the SSTs (Deployment tool) from the SWITCH
SSTs (Adapter harness).

acxuuw00001267

08-10–26
1890-1U-06H(08-10).fm 27 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

Curtain Air Bag Module
1. Remove the curtain air bag module. (See 08-10-10 CURTAIN AIR BAG MODULE REMOVAL/INSTALLATION.)
2. Remove the nuts. NUT
3. Remove the curtain air bag module from the
CURTAIN AIR
bracket. BAG MODULE

BRACKET
ac9uuw00001909

4. Secure the curtain air bag module in a vise, and

cut off the deployment section, as shown in the
CUT
figure. 450 mm {17.7in} OR MORE

Warning
• Be sure not to crush the pipe on the side
where it is cut. If it is crushed completely,
the interior pressure of the pipe will build
up and can cause it to explode during air
bag module operation (deployment). CURTAIN AIR BAG MODULE
08-10
ac9uuw00001910

5. Connect the SST (Adapter harness) to the

curtain air bag module as shown in the figure.
49 D066 002

ac9uuw00001908

6. Secure the curtain air bag module to the tire, by

wrapping a wire (cross section 1.25 mm2 {0.002 WIRE

in2} or more) through the tire and the bolt

installation holes at least 4 times as shown in the
figure.
CURTAIN AIR BAG
Warning MODULE
• If the air bag module is not properly
installed to the tire, serious injury may
occur when the module is operated TIRE
(deployed). Make sure to install the air
bag module securely. acxuuw00001288

08-10–27
1890-1U-06H(08-10).fm 28 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

7. Stack the tire with the curtain air bag module on TIRE WITH
top of two tires without wheels. Stack a tire CURTAIN AIR BAG
without a wheel on top of the tire with the curtain MODULE TIRE WITH
air bag module, and then stack another tire with a WHEEL
wheel on the very top.

TIRE
WITHOUT
WHEEL

acxuuw00001289

8. Secure the tires with wire.

acxuuw00001276

9. Connect the SST (Deployment tool) to the SST

(Adapter harness).
10. Connect the SST (Deployment tool) to the
battery. Connect the power supply red clip to the 49 L066 002
positive battery terminal, and the black clip to the
negative battery terminal.
11. Verify that the red lamp on the SST (Deployment
tool) is illuminated. 49 H066 002
12. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle.

acxuuw00001290

13. Press the activation switch on the SST

(Deployment tool) to operate (deploy) the curtain
49 H066 002
air bag module.
ACTIVATION
14. Disconnect the SSTs (Deployment tool) from the SWITCH
SSTs (Adapter harness).

acxuuw00001267

08-10–28
1890-1U-06H(08-10).fm 29 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

Pre-tensioner Seat Belt
1. Remove the pre-tensioner seat belt.
(See 08-11-2 FRONT SEAT BELT REMOVAL/INSTALLATION.)
2. Connect the SST (Adapter harness) to the pre-
tensioner seat belt as shown in the figure.

49 L066 002

ac9uuw00000758

3. Put the pre-tensioner seat belt inside the tire and

secure it to the tire by wrapping a wire (cross
section of 1.25mm2 {0.002in2} or more) through TIRE
WIRE
the tire and the bolt installation holes at least 4
times.

Warning
• If the pre-tensioner seat belt is not
properly installed to the tire, serious
injury may occur when the pre-tensioner PRE-TENSIONER 08-10
part is operated (deployed). When SEAT BELT
installing the pre-tensioner seat belt to acxuuw00001291
the tire, make sure the pre-tensioner part
is inside the tire.

4. Stack the tire with the pre-tensioner seat belt on

to of two tires without wheels. Stack a tire without TIRE WITH
WHEEL
a wheel on top of the tire with the pre-tensioner TIRE
seat belt, and then stack another tire with a wheel WITHOUT
on the very top. WHEEL

TIRE WITH
PRE-TENSIONER
SEAT BELT

acxuuw00001292

5. Secure the tires with wire.

acxuuw00001276

08-10–29
1890-1U-06H(08-10).fm 30 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

6. Connect the SST (Deployment tool) to the SST
(Adapter harness).
7. Connect the SST (Deployment tool) to the
battery. Connect the power supply red clip to the 49 L066 002
positive battery terminal, and the black clip to the
negative battery terminal. 49 H066 002
8. Verify that the red lamp on the SST (Deployment
tool) is illuminated.
9. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle.

acxuuw00001293

10. Press the activation switch on the SST

(Deployment tool) to operate (deploy) the pre-
49 H066 002
tensioner seat belt.
ACTIVATION
11. Disconnect the SSTs (Deployment tool) from the SWITCH
SSTs (Adapter harness).
End Of Sie

acxuuw00001267

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES

id081000801200

Warning
• A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy)
when it is disposed of and cause serious injury. Always refer to the “AIR BAG MODULE AND PRE-
TENSIONER SEAT BELT DEPLOYMENT PROCEDURES” and dispose of air bag modules and pre-
tensioner seat belts in a deployed condition.
• The air bag modules and the pre-tensioner seat belts are very hot immediately after they are
deployed. You can be burned. Do not touch an air bag module and pre-tensioner seat belt for at
least 15 min after deployment.
• Pouring water on the deployed air bag module and pre-tensioner seat belt is dangerous. The water
will mix with the residual gases to form a gas that can make breathing difficult. Do not pour water
on the deployed air bag module and pre-tensioner seat belt.
• The deployed air bag module or pre-tensioner seat belt may contain deposits of sodium
hydroxide, a caustic byproduct of the gas-generated combustion. If this substance gets into your
eyes or on your hands, it can cause irritation and itching. When handling the deployed air bag
module and pre-tensioner seat belt, wear gloves and safety glasses.
• Due to the adoption of 2-step deployment control in both the driver and passenger-side air bag
modules, depending on the impact force, it is possible that inflator No.2 might not operate
(deploy). Before disposing of the air bag module, always follow the inflator deployment
procedures and verify the complete operation (deployment) of inflators No.1 and 2.

1. Remove the deployed air bag module or pre-tensioner seat belt.

2. Put the air bag module or pre-tensioner seat belt
in a plastic bag, seal the bag, and then dispose of
it.
End Of Sie
WM: DEPLOYMENT TOOL

acxuuw00002421

08-10–30
1890-1U-06H(08-10).fm 31 ページ ２００６年１２月１９日　火曜日　午後１時９分

AIR BAG SYSTEM

INSPECTION OF SST (DEPLOYMENT TOOL)
id081000801000
1. Before using the SST (49 H066 002), inspect its
operation. POWER SUPPLY CLIP CONNECTOR B

49 H066 002

GREEN
LIGHT

ACTIVATION SWITCH
CONNECTOR A
RED LIGHT
acxuuw00002419

Inspection Procedure
1. Follow the steps below to inspect the SST (49 H066 002).
• If not as indicated in the table, replace the SST (49 H066 002) because it has a malfunction.

Warning
• Do not use a malfunctioning SST (49 H066 002), otherwise it could cause the air bag module or
pre-tensioner seat belt to accidentally operate (deploy).

Caution
• Because the permissible voltage for the
SST (49 H066 002) is 12 V, do not connect RED CLIP 08-10
a 24 V power source because it will
damage the SST. Always connect only a
12 V power source.

Light condition
Step Inspection procedure
Green Red
BLACK CLIP
Connect the power supply 49 H066 002
red clip to the positive
1 battery terminal, and the On Off
black clip to the negative 49 H066 002
battery terminal. ACTIVATION
Connect connectors A and SWITCH
2 Off On
B.
3 Press the activation switch. On Off
CONNECTOR B
End Of Sie CONNECTOR A

acxuuw00002420

08-10–31
1890-1U-06H(08-11).fm 1 ページ ２００６年１２月１９日　火曜日　午後１時４８分

SEAT BELT
08-11 SEAT BELT
SEAT BELT LOCATION INDEX . . . . . . . 08-11–1 ALR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-11–6
FRONT SEAT BELT Load Limiter Retractor. . . . . . . . . . . . . . 08-11–6
REMOVAL/INSTALLATION. . . . . . . . . . 08-11–2 FRONT BUCKLE
ADJUSTER ANCHOR REMOVAL/INSTALLATION . . . . . . . . . . 08-11–6
REMOVAL/INSTALLATION. . . . . . . . . . 08-11–3 SECOND-ROW BUCKLE
SECOND-ROW CENTER SEAT BELT REMOVAL/INSTALLATION . . . . . . . . . . 08-11–6
REMOVAL/INSTALLATION. . . . . . . . . . 08-11–3 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-11–6
SECOND-ROW SEAT BELT RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-11–7
REMOVAL/INSTALLATION. . . . . . . . . . 08-11–4 THIRD-ROW BUCKLE
THIRD-ROW SEAT BELT REMOVAL/INSTALLATION . . . . . . . . . . 08-11–7
REMOVAL/INSTALLATION. . . . . . . . . . 08-11–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . 08-11–7
SEAT BELT INSPECTION. . . . . . . . . . . . 08-11–5 Installation . . . . . . . . . . . . . . . . . . . . . . . 08-11–7
Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-11–5 BUCKLE SWITCH INSPECTION . . . . . . . 08-11–8
ELR . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-11–5

End of Toc
SEAT BELT LOCATION INDEX
WM: SEAT BELT

id081100804200

4 3 2 1
7 6 5

08-11

ac9uuw00000575

1 Front buckle 4 Second-row seat belt

(See 08-11-6 FRONT BUCKLE REMOVAL/ (See 08-11-4 SECOND-ROW SEAT BELT
INSTALLATION.) REMOVAL/INSTALLATION.)
(See 08-11-8 BUCKLE SWITCH INSPECTION.) (See 08-11-5 SEAT BELT INSPECTION.)
2 Front seat belt 5 Second-row center seat belt
(See 08-11-2 FRONT SEAT BELT REMOVAL/ (See 08-11-6 SECOND-ROW BUCKLE REMOVAL/
INSTALLATION.) INSTALLATION.)
(See 08-11-3 ADJUSTER ANCHOR REMOVAL/ 6 Third-row seat belt
INSTALLATION.) (See 08-11-5 THIRD-ROW SEAT BELT REMOVAL/
(See 08-11-5 SEAT BELT INSPECTION.) INSTALLATION.)
3 Second-row buckle (See 08-11-5 SEAT BELT INSPECTION.)
(See 08-11-6 SECOND-ROW BUCKLE REMOVAL/ 7 Third-row buckle
INSTALLATION.) (See 08-11-7 THIRD-ROW BUCKLE REMOVAL/
INSTALLATION.)

End Of Sie
WM: FRONT SEAT BELT

08-11–1
1890-1U-06H(08-11).fm 2 ページ ２００６年１２月１９日　火曜日　午後１時４８分

SEAT BELT
FRONT SEAT BELT REMOVAL/INSTALLATION
id081100800600

Warning
• Handling the front seat belt (pre-tensioner seat belt) improperly can accidentally deploy the pre-
tensioner seat belt, which may seriously injure you. Read the service warnings and cautions
before handling the front seat belt (pre-tensioner seat belt). (See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.) (See 08-10-5 AIR BAG SYSTEM SERVICE CAUTIONS.)
• Side air bag sensor No.1 is attached to the lower part of the B-pillar. When working around the B-
pillar, disconnect the negative battery cable or work carefully, avoiding excessive impact to the
lower part of the B-pillar.

Caution
• The ELR (emergency locking retractor) has a spring that will unwind if the retractor cover is
removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly.
Therefore, do not disassemble the retractor.

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove the front scuff plate inner. (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
4. Remove the rear scuff plate inner. (See 09-17-24 REAR SCUFF PLATE REMOVAL/INSTALLATION.)
5. Remove the cover by pulling it in the direction of the arrow.
BOLT B
38.2—78.4 {3.90—7.99, 28.2—57.8}
PASSENGER SEAT ADJUSTER
ANCHOR COVER

TAB A FRONT SEAT BELT

BOLT C
A 7.8—10.3 {79.6—110.1,
CC 69.1—95.5}
D
TAB B B
DC PRE-TENSIONER SEAT
BELT CONNECTOR

BOLT B
38.2—78.4 {3.90—7.99, FRONT
BOLT A 28.2—57.8}
TAB C 36.3—54.0
COVER {3.71—5.50, COVER
26.8—39.8}

TAB D
BOLT A
38.2—78.4 {3.90—7.99,
28.2—57.8}
N·m {kgf·m, ft·lbf}

ac9uuw00000323

6. Remove the bolt A.

7. Remove the B-pillar lower trim. (See 09-17-20 B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
8. Remove the adjuster anchor cover.
9. Remove the bolt B and bolt C, then remove the front seat belt.
10. Using a screwdriver, pry out the pre-tensioner
seat belt connector’s stopper plate.
11. Disconnect the pre-tensioner seat belt connector.
12. Install in the reverse order of removal.
13. Turn the ignition switch to the ON position.
14. Verify that the air bag system warning light
illuminates for approx. 6 s and goes out.
• If the air bag system warning light does not
STOPPER
operate, refer to the on-board diagnostic PLATE
system (air bag system) and perform
inspection of the system. (See 08-02-2
FLOWCHART.) PRE-TENSIONER SEAT BELT CONNECTOR
am8rrw00000610
End Of Sie

08-11–2
1890-1U-06H(08-11).fm 3 ページ ２００６年１２月１９日　火曜日　午後１時４８分

SEAT BELT
ADJUSTER ANCHOR REMOVAL/INSTALLATION
id081100802000

Warning
• Side air bag sensor No.1 is attached to the lower part of the B-pillar. When working around the B-
pillar, disconnect the negative battery cable or work carefully, avoiding excessive impact to the
lower part of the B-pillar.
1. Turn the ignition switch to the LOCK position.
2. Disconnect the negative battery cable.
3. Remove the following parts:
(1) Front scuff plate inner (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(2) Rear scuff plate inner (See 09-17-24 REAR SCUFF PLATE REMOVAL/INSTALLATION.)
(3) Front seat belt lower anchor installation bolt (See 08-11-2 FRONT SEAT BELT REMOVAL/INSTALLATION.)
(4) B-pillar lower trim (See 09-17-20 B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
(5) Front seat belt upper anchor installation bolt (See 08-11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
(6) B-pillar upper trim (See 09-17-20 B-PILLAR UPPER TRIM REMOVAL/INSTALLATION.)
4. Remove the bolt.
5. Rotate the adjuster anchor in the direction of the BOLT
38.2—78.4
arrow. {3.90—7.99, 28.2—57.8}
6. Remove the adjuster anchor by pulling it outward.
7. Install in the reverse order of removal.
End Of Sie
WM: REAR SEAT BELT
ADJUSTER
ANCHOR

08-11
N·m {kgf·m, ft·lbf}
ac9uuw00000767
SECOND-ROW CENTER SEAT BELT REMOVAL/INSTALLATION
id081100802400

Caution
• The ELR (emergency locking retractor) has a spring that will unwind if the retractor cover is
removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly.
Therefore, do not disassemble the retractor.
1. Turn the ignition switch to the LOCK position.
2. Disconnect the negative battery cable.
3. Remove the following parts:
(1) A-pillar trim (See 09-17-19 A-PILLAR TRIM REMOVAL/INSTALLATION.)
(2) Front scuff plate inner (See 09-17-23 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(3) Rear scuff plate inner (See 09-17-24 REAR SCUFF PLATE REMOVAL/INSTALLATION.)
(4) Front seat belt lower anchor installation bolt (See 08-11-2 FRONT SEAT BELT REMOVAL/INSTALLATION.)
(5) B-pillar lower trim (See 09-17-20 B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
(6) Front seat belt upper anchor installation bolt (See 08-11-2 FRONT SEAT BELT REMOVAL/
INSTALLATION.)
(7) B-pillar upper trim (See 09-17-20 B-PILLAR UPPER TRIM REMOVAL/INSTALLATION.)
(8) Trunk box (See 09-17-29 TRUNK BOX REMOVAL/INSTALLATION.)
(9) Seat side box (See 09-17-29 SEAT SIDE BOX REMOVAL/INSTALLATION.)
(10)Trunk end trim (See 09-17-28 TRUNK END TRIM REMOVAL/INSTALLATION.)
(11)Third-row seat (See 09-13-22 THIRD-ROW SEAT REMOVAL/INSTALLATION.)
(12)Third-row seat belt lower anchor installation bolt (See 08-11-5 THIRD-ROW SEAT BELT REMOVAL/
INSTALLATION.)
(13)Trunk side trim (See 09-17-27 TRUNK SIDE TRIM REMOVAL/INSTALLATION)
(14)Roof side trim (See 09-17-21 ROOF SIDE TRIM REMOVAL/INSTALLATION.)
(15)Second-row seat belt upper anchor installation bolt (See 08-11-4 SECOND-ROW SEAT BELT REMOVAL/
INSTALLATION.)
(16)C-pillar trim (See 09-17-21 C-PILLAR TRIM REMOVAL/INSTALLATION.)
(17)Third-row seat belt upper anchor installation bolt (See 08-11-5 THIRD-ROW SEAT BELT REMOVAL/
INSTALLATION.)
(18)D-pillar trim (See 09-17-22 D-PILLAR TRIM REMOVAL/INSTALLATION.)
(19)Front map light (See 09-18-29 FRONT MAP LIGHT REMOVAL/INSTALLATION.)
(20)Sunvisor (See 09-17-31 SUNVISOR REMOVAL/INSTALLATION.)
(21)Assist handle (See 09-17-31 ASSIST HANDLE REMOVAL/INSTALLATION.)
(22)RES unit cover (Vehicles with RES) (See 09-20-22 RES UNIT REMOVAL/INSTALLATION.)
(23)Headliner (See 09-17-32 HEADLINER REMOVAL/INSTALLATION.)

08-11–3
1890-1U-06H(08-11).fm 4 ページ ２００６年１２月１９日　火曜日　午後１時４８分

SEAT BELT
4. Remove the bolt.
5. Remove the second-row center seat belt. SECOND-ROW CENTER
SEAT BELT
6. Install in the reverse order of removal.
End Of Sie

BOLT
7.8—10.8 N·m
{79.6—110 kgf·cm,
69.1—95.5 in·lbf} BOLT
7.8—10.8 N·m
BOLT {79.6—110 kgf·cm,
39—78 N·m 69.1—95.5 in·lbf}
{3.9—7.9 kgf·m, 69.1—95.5 ft·lbf}
ac9uuw00000557

SECOND-ROW SEAT BELT REMOVAL/INSTALLATION

id081100802500

Caution
• The ELR (emergency locking retractor) has a spring that will unwind if the retractor cover is
removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly.
Therefore, do not disassemble the retractor.

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable.
3. Remove the following parts:
(1) Trunk box (See 09-17-29 TRUNK BOX REMOVAL/INSTALLATION.)
(2) Seat side box (See 09-17-29 SEAT SIDE BOX REMOVAL/INSTALLATION.)
(3) Trunk end trim (See 09-17-28 TRUNK END TRIM REMOVAL/INSTALLATION.)
(4) Third-row seat (See 09-13-22 THIRD-ROW SEAT REMOVAL/INSTALLATION.)
(5) Third-row seat belt lower anchor installation bolt (See 08-11-5 THIRD-ROW SEAT BELT REMOVAL/
INSTALLATION.)
(6) Rear scuff plate inner (See 09-17-24 REAR SCUFF PLATE REMOVAL/INSTALLATION.)
(7) Trunk side trim (See 09-17-27 TRUNK SIDE TRIM REMOVAL/INSTALLATION.)
4. Remove the cover.
COVER
5. Remove the bolt.
BOLT
6. Remove the second-row seat belt. 38.2—78.4 SECOND-ROW
7. Install in the reverse order of removal. {3.90—7.99, SEAT BELT
End Of Sie 28.2—57.8}

38.2—78.4
{3.90—7.99,
28.2—57.8}
BOLT

FRONT
BOLT
38.2—78.4
{3.90—7.99,
28.2—57.8}

N·m {kgf·m, ft·lbf}

ac9uuw00000388

08-11–4
1890-1U-06H(08-11).fm 5 ページ ２００６年１２月１９日　火曜日　午後１時４８分

SEAT BELT
THIRD-ROW SEAT BELT REMOVAL/INSTALLATION
id081100802600

Caution
• The ELR (emergency locking retractor) has a spring that will unwind if the retractor cover is
removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly.
Therefore, do not disassemble the retractor.

1. Remove the following parts:

(1) Trunk box (See 09-17-29 TRUNK BOX REMOVAL/INSTALLATION.)
(2) Seat side box (See 09-17-29 SEAT SIDE BOX REMOVAL/INSTALLATION.)
(3) Trunk end trim (See 09-17-28 TRUNK END TRIM REMOVAL/INSTALLATION.)
(4) Third-row seat (See 09-13-22 THIRD-ROW SEAT REMOVAL/INSTALLATION.)
2. Remove the bolt A.
COVER
3. Remove the rear scuff plate inner. (See 09-17-24 38.2—78.4
REAR SCUFF PLATE REMOVAL/ {3.90—7.99,
INSTALLATION.) 28.2—57.8}
4. Remove the trunk side trim. (See 09-17-27 BOLT B
TRUNK SIDE TRIM REMOVAL/INSTALLATION.) THIRD-ROW
5. Remove the cover. SEAT BELT
6. Remove the bolt B.
BOLT B
7. Remove the third-row seat belt. 38.2—78.4
8. Install in the reverse order of removal. {3.90—7.99,
End Of Sie
WM: SEAT BELT
28.2—57.8}

FRONT

08-11
BOLT A
38.2—78.4
{3.90—7.99,
28.2—57.8} N·m { kgf·m, ft·lbf}
ac9uuw00000324

SEAT BELT INSPECTION

id081100800300
Belt
1. Verify that the belt is installed properly with no twists or kinks.
2. Verify that there is no damage to the seat belt and no deformation of the metal fittings.
• If there is any malfunction, replace the seat belt.

ELR
1. Verify that the belt can be pulled out smoothly,
and that it retracts smoothly.
• If there is any malfunction, replace the seat
belt.
2. Verify that the retractor locks when the belt is
pulled quickly.
• If there is any malfunction, replace the seat
belt.
3. Remove the retractor.

ac9uuw00002406

4. While pulling the seat belt out, make sure that the
seat belt does not lock when the retractor is tilted
slowly up to 15° from the mounted position and
locks when the retractor is tilted 40° or more.
• If there is any malfunction, replace the seat
belt.

RETRACTOR

ac9uuw00002407

08-11–5
1890-1U-06H(08-11).fm 6 ページ ２００６年１２月１９日　火曜日　午後１時４８分

SEAT BELT
ALR
1. Pull the belt out fully to change the lock mode from ELR to ALR.
2. Verify that retractor makes a clicking sound as the belt slowly retracts. If no sound is heard, the lock mode has
not changed to ALR. If necessary, repeat Step 1.
• If there is any malfunction, replace the seat belt.
3. Verify that the retractor locks when pulled.
• If there is any malfunction, replace the seat belt.
4. Verify that the lock mode changes to ELR when the belt is fully pulled out.
• If there is any malfunction, replace the seat belt.

Load Limiter Retractor

Warning
• When the load limiter operates, the belt and anchor rub against each other strongly leaving wear
tracks. If the seat belt is used in this state, the seat belt will not function at its full capability and
there is the possibility of serious injury to passengers. Be sure to replace the seat belt once the
load limiter operates.

1. If the vehicle has been subjected to a shock in an

accident, pull the belt from the retractor and
confirm that there are no wear tracks (the load
limiter has not operated) by visually inspecting
BELT ANCHOR
and feeling the belt.
• If there is any malfunction, replace the seat
belt.
End Of Sie
WM: FRONT BUCKLE

TRACE
PULL OF WEAR

ac9uuw00002408

FRONT BUCKLE REMOVAL/INSTALLATION

id081100800400
1. Remove the front seat. (See 09-13-3 FRONT SEAT REMOVAL/INSTALLATION.)
2. Remove the side cover No.1. (See 09-13-3 FRONT SEAT DISASSEMBLY/ASSEMBLY.)
3. Remove the bolt.
4. Remove the front buckle.
5. Install in the reverse order of removal. FRONT BUCKLE
End Of Sie
WM: REAR BUCKLE

38.2—78.4
{3.90—7.99,28.2—57.8}
BOLT
N·m {kgf·m, ft·lbf}
ac9uuw00000768

SECOND-ROW BUCKLE REMOVAL/INSTALLATION

id081100802100
LH
1. Remove the second-row seat (LH). (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
2. Remove the bolt A.
3. Remove the second-row center buckle.
4. Remove the second-row seat (LH) seat cushion
pad. (See 09-13-20 SECOND-ROW SEAT
DISASSEMBLY/ASSEMBLY.) SECOND-ROW A
5. Remove the bolt B. CENTER
6. Remove the second-row buckle (LH). BUCKLE
SECOND-ROW
7. Install in the reverse order of removal. BUCKLE (LH) BOLT B
38.2—78.4
38.2—78.4 {3.90—7.99 , 28.2—57.8}
{3.90—7.99, A
28.2—57.8} BOLT A N·m {kgf·m, ft·lbf}
ac9uuw00000765

08-11–6
1890-1U-06H(08-11).fm 7 ページ ２００６年１２月１９日　火曜日　午後１時４８分

SEAT BELT
RH
1. Remove the second-row seat (RH). (See 09-13-19 SECOND-ROW SEAT REMOVAL/INSTALLATION.)
2. Remove in bolt.
3. Remove the second-row buckle (RH).
4. Install in the reverse order of removal.
End Of Sie

38.2—78.4
{3.90—7.99, 28.2—57.8}
SECOND-ROW
BOLT
BUCKLE (RH) N·m {kgf·m, ft·lbf}
ac9uuw00000766

THIRD-ROW BUCKLE REMOVAL/INSTALLATION

id081100802300
Removal
1. Fold the third-row seat backs forward.
2. Remove the trunk box. (See 09-17-29 TRUNK BOX REMOVAL/INSTALLATION.)
3. Remove the bolt. BOLT
4. Remove the third-row buckle. THIRD-ROW BUCKLE

08-11

ac9uuw00000325

Installation
1. Bind the third-row seat belt buckles in a band as
shown in the figure. THIRD-ROW
BUCKLE
BAND
BAND

THIRD-ROW
BUCKLE

ac9uuw00002476

2. Install the bolt. BOLT

3. Remove the trunk box. (See 09-17-29 TRUNK THIRD-ROW BUCKLE 38.2—78.4
BOX REMOVAL/INSTALLATION.) {3.90—7.99,
28.2—57.8}
End Of Sie
WM: FRONT BUCKLE

N·m {kgf·m, ft·lbf}

ac9uuw00002477

08-11–7
1890-1U-06H(08-11).fm 8 ページ ２００６年１２月１９日　火曜日　午後１時４８分

SEAT BELT
BUCKLE SWITCH INSPECTION
id081100803000
1. Inspect for continuity between the buckle switch
terminals using a tester.
• If not as indicated in the table, replace the
A
front buckle.
B A
: Continuity
Terminal
Seat belt
A B
B
Fastened
Unfastened
acxuuw00002102
ampjjw00002805
End Of Sie

08-11–8
1890-1U-06H(08-60).fm 1 ページ ２００６年１２月１９日　火曜日　午後１時４９分

SERVICE TOOLS
08-60 SERVICE TOOLS
RESTRAINTS SST . . . . . . . . . . . . . . . . . 08-60–1

End of Toc
RESTRAINTS SST
WM: RESTRAINTS

id086000800100

49 H066 002 49 B066 004 49 L066 002

Deployment Adapter Adapter

tool harness harness

49 G066 003 49 D066 002 49 N088 0A0

Adapter Adapter Fuel and

harness harness Thermometer
checker

End Of Sie 08-60

08-60–1
1890-1U-06H(09-02A).fm 1 ページ ２００６年１２月１９日　火曜日　午後１時５０分

BODY & ACCESSORIES 09

SECTION

Toc of SCT
ON-BOARD DIAGNOSTIC SYMPTOM
[POWER LIFTGATE (PLG) TROUBLESHOOTING[POWER
SYSTEM]. . . . . . . . . . . . . . . . . 09-02A WINDOW SYSTEMS
ON-BOARD DIAGNOSTIC (AUTO-OPEN/CLOSE
[ADVANCED KEYLESS FUNCTION)]. . . . . . . . . . . . . . 09-03B
SYSTEM]. . . . . . . . . . . . . . . . . 09-02B SYMPTOM
ON-BOARD TROUBLESHOOTING[POWER
DIAGNOSTIC[IMMOBILIZER WINDOW SYSTEMS
SYSTEM (ADVANCED (EXTERIOR OPEN/CLOSE
KEYLESS SYSTEM)] . . . . . . . 09-02C FUNCTION)]. . . . . . . . . . . . . . 09-03C
ON-BOARD SYMPTOM TROUBLESHOOTING
DIAGNOSTIC[IMMOBILIZER [ADVANCED KEYLESS
SYSTEM (KEYLESS ENTRY SYSTEM] . . . . . . . . . . . . . . . . 09-03D
SYSTEM)] . . . . . . . . . . . . . . . . 09-02D SYMPTOM
ON-BOARD DIAGNOSTIC TROUBLESHOOTING[KEYLESS
[AUTO LIGHT/WIPER ENTRY SYSTEM]. . . . . . . . . . 09-03E 09-02A
CONTROL MODULE] . . . . . . . 09-02E SYMPTOM
ON-BOARD DIAGNOSTIC TROUBLESHOOTING[ENTIRE
[AUDIO (STANDARD AUDIO SYSTEM] . . . . . . . . . . 09-03F
AUDIO)]. . . . . . . . . . . . . . . . . . 09-02F SYMPTOM TROUBLESHOOTING
ON-BOARD DIAGNOSTIC [RADIO] . . . . . . . . . . . . . . . . . 09-03G
[AUDIO (TOUCH PANEL SYMPTOM TROUBLESHOOTING
TYPE AUDIO)] . . . . . . . . . . . . 09-02G [CASSETTE TAPE
ON-BOARD DIAGNOSTIC PLAYER] . . . . . . . . . . . . . . . . 09-03H
[AUDIO AMPLIFIER] . . . . . . . 09-02H SYMPTOM TROUBLESHOOTING
ON-BOARD DIAGNOSTIC [CD PLAYER/CHANGER] . . . 09-03I
[HANDS-FREE TELEPHONE SYMPTOM TROUBLESHOOTING
(HF/TEL) SYSTEM]. . . . . . . . . 09-02I [CAR-NAVIGATION
ON-BOARD SYSTEM] . . . . . . . . . . . . . . . . 09-03J
DIAGNOSTIC[INSTRUMENT SYMPTOM TROUBLESHOOTING
CLUSTER] . . . . . . . . . . . . . . . 09-02J [REAR ENTERTAINMENT
ON-BOARD DIAGNOSTIC SYSTEM (RES)]. . . . . . . . . . . 09-03K
[BCM] . . . . . . . . . . . . . . . . . . . 09-02K SYMPTOM TROUBLESHOOTING
ON-BOARD DIAGNOSTIC [HANDS-FREE TELEPHONE
[MULTIPLEX COMMUNICATION (HF/TEL) SYSTEM] . . . . . . . . 09-03L
SYSTEM]. . . . . . . . . . . . . . . . . 09-02L SYMPTOM TROUBLESHOOTING
SYMPTOM [INSTRUMENT
TROUBLESHOOTING[POWER CLUSTER] . . . . . . . . . . . . . . . 09-03M
LIFTGATE (PLG) BODY PANELS. . . . . . . . . . . . . 09-10
SYSTEM]. . . . . . . . . . . . . . . . . 09-03A DOORS AND LIFTGATE . . . . . 09-11
GLASS/WINDOWS/
MIRRORS. . . . . . . . . . . . . . . . 09-12
SEATS . . . . . . . . . . . . . . . . . . . 09-13

09-02A–1
1890-1U-06H(09-02A).fm 2 ページ ２００６年１２月１９日　火曜日　午後１時５０分

ON-BOARD DIAGNOSTIC [POWER LIFTGATE (PLG) SYSTEM]

SECURITY AND LOCKS . . . . . 09-14 POWER SYSTEMS . . . . . . . . . 09-21
SUNROOF . . . . . . . . . . . . . . . . 09-15 INSTRUMENTATION/
EXTERIOR TRIM . . . . . . . . . . . 09-16 DRIVER INFO. . . . . . . . . . . . . 09-22
INTERIOR TRIM . . . . . . . . . . . . 09-17 CONTROL SYSTEM . . . . . . . . 09-40
LIGHTING SYSTEMS . . . . . . . . 09-18 TECHNICAL DATA . . . . . . . . . 09-50
WIPER/WASHER SYSTEM . . . 09-19 SERVICE TOOLS. . . . . . . . . . . 09-60
ENTERTAINMENT . . . . . . . . . . 09-20
Toc of SCT
09-02A ON-BOARD DIAGNOSTIC [POWER LIFTGATE
(PLG) SYSTEM]
FOREWORD [POWER LIFTGATE (PLG) DTC B266B [POWER LIFTGATE (PLG)
SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–2 SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–13
Outline. . . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–2 DTC B266C [POWER LIFTGATE (PLG)
SYSTEM WIRING DIAGRAM [POWER SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–14
LIFTGATE (PLG) SYSTEM] . . . . . . . . . . 09-02A–3 DTC B266E [POWER LIFTGATE (PLG)
DTC INSPECTION [POWER LIFTGATE SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–15
(PLG) SYSTEM] . . . . . . . . . . . . . . . . . . . 09-02A–3 DTC B267A [POWER LIFTGATE (PLG)
DTC TABLE [POWER LIFTGATE SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–16
(PLG) SYSTEM] . . . . . . . . . . . . . . . . . . . 09-02A–4 DTC B267B [POWER LIFTGATE (PLG)
CLEARING DTC [POWER LIFTGATE SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–18
(PLG) SYSTEM] . . . . . . . . . . . . . . . . . . . 09-02A–5 DTC B267C [POWER LIFTGATE (PLG)
PID/DATA MONITOR INSPECTION SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–19
[POWER LIFTGATE (PLG) DTC B2699 [POWER LIFTGATE (PLG)
SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–5 SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–20
PID/DATA MONITOR TABLE [POWER DTC B2700 [POWER LIFTGATE (PLG)
LIFTGATE (PLG) SYSTEM] . . . . . . . . . . 09-02A–6 SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–21
DTC B1311 [POWER LIFTGATE (PLG) DTC B2701 [POWER LIFTGATE (PLG)
SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–8 SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–22
DTC B1318 [POWER LIFTGATE (PLG) DTC B2702 [POWER LIFTGATE (PLG)
SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–9 SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–23
DTC B1342 [POWER LIFTGATE (PLG) DTC B2821 [POWER LIFTGATE (PLG)
SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–10 SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–24
DTC B241A [POWER LIFTGATE (PLG) DTC B2936 [POWER LIFTGATE (PLG)
SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 09-02A–11 SYSTEM] . . . . . . . . . . . . .