Precaution: Caution

5-1 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Precaution
1. Precaution
A: SUPPLEMENTAL RESTRAINT
SYSTEM “AIRBAG”
Airbag system wiring harness is routed on and
along body panels.
CAUTION:
I All Airbag system wiring harness and connec-
tors are colored yellow. Do not use electrical test
equipment on these circuit.
I Be careful not to damage Airbag system wiring
harness when repairing the body panel.
2
SPECIFICATIONS AND SERVICE DATA [S1A0] 5-1
1. Precaution
MEMO:
3
5-1 [S200] SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points

Various master repair locations are established as datum points used during body repairs. In addition, guide
holes, locators and indents are provided to facilitate panel replacement and achieve alignment accuracy.
NOTE:
Left and right datum points are all symmetrical to each other.
A: ENGINE COMPARTMENT AND ROOM
1. SEDAN AND WAGON
H5M0815A
4
(1) Radiator panel (UPR) repair bolt (10) Hood hinge attaching bolt hole (20) Center pillar gauge hole 10 mm
hole M8 (Right) M8 (Symmetrical) (0.39 in) dia. (Symmetrical)
(2) Radiator panel (UPR) repair bolt (11) Cowl panel mounting hole 5 mm (21) Belt anchor attaching bolt hole
hole M8 (Left) (0.20 in) dia. (Located in center (Symmetrical)
(3) Fender attaching bolt hole M6 of vehicle.) (22) Wax coat hole, 20 mm (0.79 in)
(Symmetrical) (12) Front rail (Inner) mirror attaching dia. (Symmetrical)
(4) Headlight attaching bolt hole M6 bolt hole 8 mm (0.31 in) dia. (23) Rear door switch attaching hole
(Symmetrical) (13) Fender attaching bolt hole M6 20 mm (0.79 in) dia. (Symmetri-
(5) Radiator panel side gauge hole (Symmetrical) cal)
24 mm (0.94 in) dia. (Symmetri- (14) Front pillar gauge hole 20 mm (24) Retainer attaching square hole 7
cal) (0.79 in) dia. (Symmetrical) mm (0.28 in) (Symmetrical)
(6) Front bumper mounting hole 14 (15) Wax coat hole, 20 mm (0.79 in) (25) Spare tire attaching bolt hole M8
x 17 mm (0.55 x 0.67 in) dia. dia. (Symmetrical) (26) Air draw hole 7 mm (0.28 in) dia.
(Symmetrical) (16) Retainer attaching square hole 7 (Symmetrical)
(7) Front crossmember attaching mm (0.28 in) (Symmetrical) (60) Fender attaching bolt hole M6
bolt hole 12.4 mm (0.488 in) dia. (17) Sun visor attaching hole 20 mm (Symmetrical)
(Symmetrical) (0.79 in) dia. (Symmetrical) (64) Door switch attaching hole 20
(8) Fender attaching bolt hole M6 (18) Retainer attaching square hole 7 mm (0.79 in) dia. (Symmetrical)
(Symmetrical) mm (0.28 in) (Symmetrical) (67) Front glass attaching hole Right
(9) Front strut mounting hole 10 mm (19) Retainer attaching square hole 7 6.5 mm (0.256 in) dia. Left 6.5 x
(0.39 in) dia. (Symmetrical) mm (0.28 in) (Symmetrical) 10 mm (0.256 x 0.39 in) dia.
5
2. COUPE
H5M0712B
6
(1) Radiator panel (UPR) repair bolt (11) Cowl panel mounting hole 5 mm (70) Door switch attaching hole 13.5
hole M8 (Right) (0.20 in) dia. (Located in center mm (0.531 in) dia. (Symmetrical)
(2) Radiator panel (UPR) repair bolt of vehicle.) (71) Retainer attaching square hole 8
hole M8 (Left) (12) Front rail (Inner) mirror attaching mm (0.31 in). (Symmetrical)
(3) Fender attaching bolt hole M6 bolt hole 8 mm (0.31 in) dia. (72) Rear quarter glass attaching
(Symmetrical) (13) Fender attaching bolt hole M6 hole 8 mm (0.31 in) dia. (Sym-
(4) Headlight attaching bolt hole M6 (Symmetrical) metrical)
(Symmetrical) (14) Front pillar gauge hole 20 mm (73) Rear quarter glass attaching
(5) Radiator panel side gauge hole (0.79 in) dia. (Symmetrical) hole 7 mm (0.28 in) dia. (Sym-
24 mm (0.94 in) dia. (Symmetri- (16) Retainer attaching square hole 7 metrical)
cal) mm (0.28 in) (Symmetrical) (74) Rear quarter glass attaching
(6) Front bumper mounting hole 14 (17) Sun visor attaching hole 20 mm hole 8 x 5.5 mm (0.31 x 0.217
x 17 mm (0.55 x 0.67 in) dia. (0.79 in) dia. (Symmetrical) in) dia. (Symmetrical)
(Symmetrical) (25) Spare tire attaching bolt hole M8 (75) Retainer attaching square hole 8
(7) Front crossmember attaching (26) Air draw hole 7 mm (0.28 in) dia. mm (0.31 in). (Symmetrical)
bolt hole 12.4 mm (0.488 in) dia. (Symmetrical) (76) Seat belt anchor attaching bolt
(Symmetrical) (60) Fender attaching bolt hole M6 hole 16 mm (0.63 in) dia. (Sym-
(8) Fender attaching bolt hole M6 (Symmetrical) metrical)
(Symmetrical) (67) Front glass attaching hole Right
(9) Front strut mounting hole 10 mm 6.5 mm (0.256 in) dia. Left 6.5 x
(0.39 in) dia. (Symmetrical) 10 mm (0.256 x 0.39 in) dia.
(10) Hood hinge attaching bolt hole (69) Wax coat hole 20 mm (0.79 in)
M8 (Symmetrical) dia. (Symmetrical)
7
5-1 [S2B1] SPECIFICATIONS AND SERVICE DATA
B: LUGGAGE COMPARTMENT AND ROOM

1. SEDAN AND COUPE
H5M0816A
8
SPECIFICATIONS AND SERVICE DATA [S2B1] 5-1
(27) Rear pillar (Inner) gauge hole 8 (33) Rear skirt (UPR) cutout (Repair (39) Steering support beam attaching
mm (0.31 in) dia. (Symmetrical) locator) bolt hole M8 (Symmetrical)
(28) Rear roof trim attaching hole 8 (34) Rear skirt gauge hole 20 mm (40) Front pillar (Inner) gauge hole 10
mm (0.31 in) dia. (Symmetrical) (0.79 in) dia. (Symmetrical) mm (0.39 in) dia. (Symmetrical)
(29) Rear quarter trim attaching hole (35) Rear combination light mounting (41) Floor mat attaching clip hole 8
8 mm (0.31 in) dia. (Symmetri- hole 9 mm (0.35 in) dia. (Sym- mm (0.31 in) dia. (Symmetrical)
cal) metrical) (66) Rear panel (Center) repair loca-
(30) Seat belt anchor attaching bolt (36) Rear quarter bumper side gauge tor (Located in center of vehicle.)
hole (Symmetrical) hole 20 mm (0.79 in) dia. (Left) (68) Rear glass attaching hole
(31) Reinforcement (Rear panel rear) (37) Rear quarter bumper side gauge (Right): 6.5 mm (0.256 in) dia.
repair locator (Located in center hole 20 mm (0.79 in) dia. (Right) (Left): 6.5 x 10 mm (0.256 x 0.39
of vehicle) (38) Instrument panel attaching in) dia.
(32) Rear corner patch at flange square hole 22 x 34.5 mm (0.87
(Symmetrical) x 1.358 in) (Right)
9
2. WAGON
H5M0817A
(42) Rear quarter glass attaching (46) Rear strut mounting hole 10 mm (61) Side rail (Inner) gauge hole 8
hole 8 mm (0.31 in) dia. (Sym- (0.39 in) dia. (Symmetrical) mm (0.31 in) dia. (Symmetrical)
metrical) (47) Rear gate stay attaching bolt (62) Rear quarter trim attaching hole
(43) Roof rail attaching hole 10 mm hole M8 (Symmetrical) 8 mm (0.31 in) dia. (Symmetri-
(0.39 in) dia. (Symmetrical) (48) Child seat anchor attaching bolt cal)
(44) Rear quarter glass attaching hole (63) Rear quarter harness attaching
hole 8 x 15 mm (0.31 x 0.59 in) (49) Rear combination light mounting clip hole 7 mm (0.28 in) dia.
dia. (Symmetrical) hole 10 mm (0.39 in) dia. (Sym- (Symmetrical)
(45) Rear roof trim attaching hole 8 metrical) (65) Seat belt anchor attaching bolt
mm (0.31 in) dia. (Symmetrical) hole (Symmetrical)
10
SPECIFICATIONS AND SERVICE DATA [S2C0] 5-1
C: UNDER BODY
H5M0818A
(50) Radiator panel (LWR) frame (53) Front suspension attaching bolt (57) Rear differential attaching bolt
gauge hole 15 mm (0.59 in) dia. hole M14 hole M12 (Symmetrical)
(Symmetrical) (54) Side frame gauge hole 20 mm (58) Rear suspension attaching bolt
(51) Front side frame gauge hole 20 (0.79 in) dia. (Symmetrical) hole M12 (Symmetrical)
mm (0.79 in) dia. (Symmetrical) (55) Transmission mount attaching (59) Rear side frame gauge hole 15
(52) Front crossmember attaching bolt hole M10 (Symmetrical) mm (0.59 in) dia. (Symmetrical)
hole 12.4 mm (0.488 in) dia. (56) Side frame gauge hole 15 mm
(Symmetrical) (0.59 in) dia. (Symmetrical)
11
5-1 [S2D0] SPECIFICATIONS AND SERVICE DATA
D: DATUM POINT LOCATION
H5M0819A H5M0823A
H5M0820A
H5M0824A
H5M0825A
H5M0821A
H5M0822A H5M0826A
12
SPECIFICATIONS AND SERVICE DATA [S2D0] 5-1
H5M0827A H5M0831A
H5M0828A
H5M0832A
H5M0833A
H5M0829A
H5M0830A
H5M0834A
13
H5M0835A
H5M0839A
H5M0836A H5M0840A
H5M0841A
H5M0837A
H5M0842A
H5M0838A
14
H5M0847A
H5M0843A
H5M0848A
H5M0844A
H5M0845A
H5M0849A
H5M0846A H5M0850A
15
H5M0851A
H5M0855A
H5M0852A H5M0856A
H5M0857A
H5M0853A
H5M0854A H5M0858A
16
H5M0859A
H5M0863A
H5M0860A H5M0864A
H5M0861A H5M0865A
H5M0866A
H5M0862A
17
H5M0871A
H5M0867A
H5M0868A
H5M0872A
H5M0869A
H5M0873A
H5M0870A H5M0874A
18
H5M0875A
H5M0879A
H5M0876A H5M0880A
H5M0881A
H5M0670B
H5M0878A H5M0882A
19
H5M0883A H5M0887A
H5M0888A
H5M0884A
H5M0885A
H5M0889A
H5M0886A
20
3. Datum Dimensions
3. Datum Dimensions NOTE:

I A suffix character “R” or “L” refers to the right or
Use a tram tracking gauge to measure all dimen- the left.
sions. If a measuring tape is used, be extremely I All dimensions refer to the distance between the
careful because it tends to deflect or twist, which centers of holes measured in a straight line
results in a false reading. I Each dimension indicates a projected dimension
between hole centers.
G5M0122
A: FRONT STRUCTURE
H5M0890A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) to (9) R 525 (20.67) (10) R to (10) L 1,382 (54.41)
(11) to (9) L 525 (20.67) (3) R to (3) L 1,336 (52.60)
(11) to (6) R 988 (38.90) (5) R to (5) L 942 (37.09)
(11) to (6) L 988 (38.90) (5) R to (4) R 1,174 (46.22)
(11) to (3) R 990 (38.98) (5) L to (4) L 1,174 (46.22)
(11) to (3) L 990 (38.98) (4) R to (4) L 1,269 (49.96)
(10) R to (3) R 829 (32.64) (60) R to (13) R 1,113 (43.82)
(10) L to (3) L 829 (32.64) (60) L to (13) L 1,113 (43.82)
(10) R to (8) R 567 (22.32) (60) R to (14) R 1,076 (42.36)
(10) L to (8) L 567 (22.32) (60) L to (14) L 1,076 (42.36)
(8) R to (3) R 264 (10.39) (1) to (11) 882 (34.72)
(8) L to (3) L 264 (10.39) (2) to (11) 913 (35.94)
21
3. Datum Dimensions
B: CENTER STRUCTURE
H5M0891A
22
SPECIFICATIONS AND SERVICE DATA [S3C1] 5-1
3. Datum Dimensions
C: DOORS AND REAR QUARTER

1. SEDAN AND WAGON
H5M0892A
Unit: mm (in)
(14) to (18) 1,495 (58.86) (19) to (23) 912 (35.91)
(13) to (64) 947 (37.28) (20) to (36) L* 1,462 (57.56)
(16) to (64) 976 (38.43) (20) R to (37) R* 1,481 (58.31)
(20) to (23) 803 (31.61) (62) to (43) * 377 (14.84)
(20) to (24) 829 (32.64) (42) to (44) * 847 (33.35)
*: Wagon only
23
5-1 [S3C2] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
2. COUPE
H5M0713B
Unit: mm (in)
(14) to (71) 1,576 (62.05) (72) to (74) 778 (30.63)
(13) to (70) 1,251 (49.25) (73) to (75) 512 (20.16)
(16) to (70) 997 (39.25) (70) to (36) L 1,295 (50.98)
(13) to (69) 1,063 (41.85) (70) to (37) R 1,243 (48.94)
24
3. Datum Dimensions
D: FRONT WINDSHIELD AND REAR WINDOW
H5M0893A
Unit: mm (in)
(11) to (12) 989 (38.94) (66) to (28) L 714 (28.11)
(67) R to (67) L 1,012 (39.84) (66) to (68) R 856 (33.70)
(11) to (67) R 1,116 (43.94) (66) to (68) L 856 (33.70)
(11) to (67) L 1,116 (43.94) (68) R to (68) L 1,012 (39.84)
(66) to (28) R 714 (28.11)
25
5-1 [S3E0] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
E: TRUNK LID AND REAR GATE
H5M0894A
Unit: mm (in)
(31) to (32) R 575 (22.64) (35) R to (35) L 1,364 (53.70)
(31) to (32) L 575 (22.64) (45) R to (48) 988 (38.90)
(31) to (26) R 812 (31.97) (45) L to (48) 988 (38.90)
(31) to (26) L 812 (31.97) (45) R to (47) R 926 (36.46)
(31) to (33) 522 (20.55) (45) L to (47) L 926 (36.46)
(31) to (35) R 794 (31.26) (47) R to (47) L 1,043 (41.06)
(31) to (35) L 794 (31.26) (49) R to (49) L 1,355 (52.56)
(34) R to (34) L 890 (35.04) (34) R to (34) L 890 (35.04)
26
SPECIFICATIONS AND SERVICE DATA [S3F0] 5-1
3. Datum Dimensions
F: COMPARTMENT
H5M0895A
Unit: mm (in)
Point to point Dimension Point to point Dimension Point to point Dimension
(30) R to (30) L 1,197 (47.13) (41) to (15) R 1,140 (44.88) (41) to (30) L* 1,168 (45.98)
(21) R to (21) L 1,061 (41.77) (41) to (15) L 1,140 (44.88) (41) to (28) R* 1,050 (41.34)
(15) R to (15) L 1,453 (57.20) (41) to (22) R 733 (28.86) (41) to (28) L* 1,050 (41.34)
(22) R to (22) L 1,453 (57.20) (41) to (22) L 733 (28.86) (41) to (21) R 1,038 (40.87)
(39) R to (39) L 1,388 (54.65) (41) to (12) 1,156 (45.51) (41) to (21) L 1,038 (40.87)
(40) R to (40) L 1,401 (55.16) (41) to (27) R 1,085 (42.72) (41) to (17) R 1,208 (47.56)
(41) to (38) 1,527 (60.12) (41) to (27) L 1,085 (42.72) (41) to (17) L 1,208 (47.56)
(41) to (39) R 1,524 (60.00) (41) to (26) R 1,568 (61.73) (41) to (33) * 1,569 (61.77)
(41) to (39) L 1,524 (60.00) (41) to (26) L 1,568 (61.73) (76) R to (76) L✩ 1,212 (47.72)
(41) to (40) R 1,756 (69.13) (41) to (25) 1,184 (46.61)
(41) to (40) L 1,756 (69.13) (41) to (30) R* 1,168 (45.98)
*: Sedan only
✩ : Coupe only
27
5-1 [S3G0] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
G: LUGGAGE ROOM
H5M0896A
Unit: mm (in)
(41) to (65) R 1,122 (44.17) (41) to (43) R 1,237 (48.70)
(41) to (65) L 1,122 (44.17) (41) to (43) L 1,237 (48.70)
(41) to (45) R 1,225 (48.23) (48) to (46) R 971 (38.23)
(41) to (45) L 1,225 (48.23) (48) to (46) L 971 (38.23)
(41) to (48) 1,446 (56.93) (65) R to (65) L 1,235 (48.62)
28
SPECIFICATIONS AND SERVICE DATA [S400] 5-1
4. Datum Points and Dimensions Concerning On-Board Aiming Adjustment
4. Datum Points and Dimensions Concerning On-Board Aiming

Adjustment
If headlight aiming is misaligned due to damaged body panel, repair headlight mating surface using body
and headlight datum points as a guide.
H5M0898A
Unit: mm (in)
(11) to (A) L 993 (39.09) (11) to (B) L 1,048 (41.26)
(11) to (A) R 993 (39.09) (11) to (B) R 1,048 (41.26)
29
5-1 [C100] COMPONENT PARTS
1. Front Hood and Hood Lock
1. Front Hood and Hood Lock
H5M0671B
(1) Front hood (7) Hood lock ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Hinge (RH, LH) (8) Striker
T1: 14±9 (1.4±0.9, 10.1±6.5)
(3) Hood hinge cover (RH, LH) (9) Front hood stay
T2: 32±1 (3.3±0.1, 23.9±0.7)
(4) Lever ASSY (10) Seal (Front hood) SD
(5) Cable (11) Seal (Front hood) CTR
(6) Stopper
30
COMPONENT PARTS [C200] 5-1
2. Trunk Lid
2. Trunk Lid
H5M0900A
(1) Torsion bar (5) Trunk lid lock ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Trunk lid (6) Striker
T1: 14±4 (1.4±0.4, 10.1±2.9)
(3) Weatherstrip (7) Hinge ASSY
T2: 18±5 (1.8±0.5, 13.0±3.6)
(4) Rod
31
3. Front Bumper
3. Front Bumper
H5M0964A
(1) Plate (5) Front beam (Except USA 2500 (9) Bumper face (USA 2500 cc)
(2) Bumper face (Except USA 2500 cc)
cc) (6) Bracket (Side) Tightening torque: N·m (kg-m, ft-lb)
(3) Spacer (7) Holder upper T: 93±25 (9.5±2.5, 69±18)
(4) E/A form bumper (8) Front beam (USA 2500 cc)
32
4. Rear Bumper
4. Rear Bumper
H5M0715B
(1) Holder upper (4) E/A from bumper Tightening torque: N·m (kg-m, ft-lb)
(2) Bumper beam (5) Plate
T: 93±25 (9.5±2.5, 69±18)
(3) Bracket (Side) (6) Bumper surface
33
5. Sunroof
5. Sunroof
H5M0901A
(1) Weatherstrip (10) Harness (19) Shutting ASSY (RH)

(2) Sunroof panel (11) Sunroof trim (20) Shutting ASSY (LH)
(3) Rear guide ASSY (12) Guide rail (21) Drain tube
(4) Lower panel (13) Set bracket (22) Garnish
(5) Lower panel (14) Guide rail
(6) Rear guide ASSY (15) Motor ASSY Tightening torque: N·m (kg-m, ft-lb)
(7) Drive unit (16) Sealed tape T: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(8) Relay (17) Frame ASSY
(9) Harness (18) Sealed cushion
34
6. Steering Support Beam
6. Steering Support Beam
H5M0902A
(1) Bracket Tightening torque: N·m (kg-m, ft-lb)

(2) Steering beam
T: 18±5 (1.8±0.5, 13.0±3.6)
35
7. Guard Pipe
7. Guard Pipe
B5M0371C
(1) Guard pipe Tightening torque: N·m (kg-m, ft-lb)

(2) Rear floor panel
T: 32±10 (3.3±1.0, 23.9±7)
36
SERVICE PROCEDURE [W1A3] 5-1
1. Hood
1. Hood 2. HOOD LOCK

1) Open front hood and remove front grille.
A: REMOVAL AND INSTALLATION 2) Remove bolts which secure lock assembly to
NOTE: radiator panel, and remove lock assembly.
The hood lock has a dual locking design which
consists of a main lock and a safety lock mecha-
nism. When the release knob located at the front
pillar on the driver’s side is pulled back, the main
lock is released through the cable attached to the
knob.
The safety lock can be released by pushing the
lever protruding above the front grill while opening
the hood.
1. HOOD G5M0138
1) Open front hood, and remove washer hose.
3) Disconnect release cable from lock assembly
2) Remove attaching bolts.
4) Installation is in the reverse order of removal.
NOTE:
I Route hood lock release cable and hold with
clips.
I After installing release cable, ensure it operates
smoothly.
I Apply grease to sliding surfaces of parts.
G5M0137
3) Detach front hood from hinges.

CAUTION:
Adjust buffer assembly on each end so that
main lock is applied securely when hood is
G5M0142
released from a height of approx. 20 mm (0.79
in).
3. RELEASE CABLE
NOTE:
1) Remove front grille.
Align the center of striker with lock during installa-
2) Remove release cable from lock assembly.
tion. Make sure safety lever is properly caught by 3) Remove cable clip from engine compartment.
striker under the hood’s own weight. 4) Remove bracket from front pillar.
G5M0141
G5M0139
37
5-1 [W1B0] SERVICE PROCEDURE
2. Trunk Lid
B: POINTS TO CHECK 2. Trunk Lid

1) Check striker for bending or abnormal wear. A: REMOVAL AND INSTALLATION
2) Check safety lever for improper movement.
3) Check other levers and spring for rust formation 1. TRUNK LID
and unsmooth movement. 1) Open trunk lid.
2) Remove trunk lid mounting bolts and detach
trunk lid from hinges.
G5M0140
C: ADJUSTMENT G5M0144
1) Fore-aft and left-right adjustments Loosen 3) Installation is in the reverse order of removal.
striker mounting bolts and adjust fore-and-aft posi-
tion of striker.
2. TORSION BAR
1) Open trunk lid. Remove torsion bars from hinge
CAUTION:
links using ST.
Do not adjust striker position using the lock.
ST 927780000 REMOVER
Doing so may result in a misaligned front grille.
CAUTION:
Be careful because torsion bar quickly swings
back when released.
G5M0145
2) Remove the left and right torsion bars.

WARNING:
Be careful because trunk lid drops under its
own weight when torsion bars are removed.
G5M0143 NOTE:
Apply a coat of grease to the rotary section of
2) Up-down adjustment hinges and contact surfaces of torsion bars.
Make up-and-down adjustment of striker only
when hood does not properly contact buffer or
hood is not flush with fender, or when release cable
does not properly operate. Adjustment can be
made by adjusting the stroke length of striker after
lock assembly mounting screws are removed.
38
SERVICE PROCEDURE [W2B1] 5-1
2. Trunk Lid
3. TRUNK LID LOCK ASSEMBLY AND 7) Disconnect cable from striker.

KEY CYLINDER NOTE:
1) Remove rod of lock assembly from rod holder Be careful not to bend or break cable.
of key lock assembly.
2) Remove bolts which hold lock assembly and
remove lock assembly.
NOTE:
I Always remove rear skirt trim panel beforehand,
if so equipped.
I Be careful not to bend opener cable.
G5M0147

CAUTION:
I When installing cover to pull handle
assembly, observe the following:
I Be careful not to catch harness.
I Engage pull handle assembly pawls
G5M0146 firmly.
NOTE:
3) Remove clip and detach key cylinder from trunk After installing opener cable, ensure it moves
lid. smoothly.
B: ADJUSTMENT
NOTE:
Apply grease to sliding surfaces of lock assembly 1. TRUNK LID
and striker. 1) To adjust left-right lid positioning, loosen bolts
which hold trunk lid to hinges.
2) To adjust up-down lid alignment, place wash-
er(s) between trunk lid and hinges or move trunk
lock assembly up or down.
G5M0148
4. TRUNK LID OPENER

1) Remove driver’s seat, rear seats, center pillar G5M0149
lower cover, floor mat, rear arch cover and side sill
cover (on the driver’s side).
2) Remove all clips which hold cable.
3) Disconnect cable from pull handle assembly.
4) Remove bolts and detach pull handle assembly.
5) Loosen bolts which hold lock assembly, and
remove it.
6) Remove striker from trunk lid.
39
5-1 [W3A1] SERVICE PROCEDURE
3. Fuel Flap
3. Fuel Flap 4. Front Bumper

A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION
1. FUEL FLAP 1) Disconnect the ground cable from the battery.
1) Remove bolts which hold hinge to car body, and 2) Remove the canister.
detach fuel flap and hinge as a unit. 3) Remove the front grille.
4) Remove the parking light and headlight LH.
5) Remove the mud guard.
6) Remove bolts from side of bumper.
G5M0150

CAUTION: G5M0152
Make sure the clearance between fuel flap and
car body is equal at all points. 7) Remove bolt from lower center of bumper.
2. FUEL FLAP OPENER

1) Remove driver’s seat, rear seats, center pillar
lower cover, floor mat, rear arch cover/rear quarter
trim (wagon), and side sill cover (on the driver’s
side).
2) Remove all clips which hold cable.
3) Disconnect cable from pull handle.
4) Detach pull handle by removing bolts.
H5M0717
8) Remove bolts from lower side of bumper.
G5M0151
5) Detach fuel lock holder by turning it.

CAUTION: G5M0154
I When installing cover to pull handle
assembly, observe the following:
I Be careful not to catch harness.
I Engage pull handle assembly pawls
firmly.
I After installing opener cable, ensure it
moves smoothly.
40
5. Rear Bumper
9) Remove bolts (engine compartment side) from 5. Rear Bumper

bumper stays.
A: REMOVAL AND INSTALLATION
1. SEDAN
1) Open trunk lid. Remove trunk trim panel clips
and detach trim.
2) Disconnect license plate light connector.
3) Remove bolts from side of bumper.
G5M0156
10) Remove turn signal light connector.

11) Remove bumper assembly.
G5M0160
4) Remove bolts from bumper stay.
G5M0157

CAUTION:
I Be extremely careful to prevent scratches on
bumper face as it is made of resin.
I Be careful not to scratch the body when
G5M0161
removing or installing the bumper.
I When installing canister, insert air vent hose 5) Remove rear bumper.
of canister into the hole on body.
NOTE:
To facilitate installation of front bumper, attach
hook (located at stay) to body panel.
G5M0162
G5M0158
41
5. Rear Bumper
6) Installation is in the reverse order of removal. 2. WAGON

CAUTION: 1) Open rear gate and rear quarter trim lid.
I Be extremely careful to prevent scratches on 2) Disconnect license plate light connector.
bumper face as it is made of resin. 3) Remove bolts from side of bumper.
I Be careful not to scratch the body when 4) Remove bolts from bumper stays.
removing or installing bumper. 5) Remove bumper assembly.
NOTE:
CAUTION:
To facilitate installation of rear bumper, attach hook
I Be extremely careful to prevent scratches on
(located at stay) to body panel. bumper face as it is made of resin.
I Be careful not to scratch the body when
removing or installing bumper.
NOTE:
To facilitate installation of rear bumper, attach hook
(located at stay) to body panel.
G5M0163
G5M0163
42
6. Coating Method for PP Bumper
6. Coating Method for PP Bumper

A: PROCESS STEPS
Process No. Process name Job contents
1 Bumper mounting Set bumper on paint worktable if required.
Use paint worktable conforming to inner
shape of bumper when possible.
G5M0164
2 Masking Mask specified part (black base) with masking tape. Use masking tape for PP
(example, Nichiban No. 533, etc.).
3 Degreasing, cleaning Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt,
oil, fat, etc.
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
5 Drying Dry at normal temperature [10 to 15 min. at 20°C (68°F)]. In half-dried condition, PP
primer paint is dissolved by solvent, e.g. thinner, etc. Therefore, if dust or dirt must be
removed, use ordinary alcohol, etc.
6 Top coat paint (I) Solid color Metallic color
Use section (block) paint for top coat. Use section (block) paint for top coat.
I Paint in use (for each color): I Paint in use (for each color):
Solid paint Metallic paint
Hardener PB Hardener PB
Thinner T-301 Thinner T-306
I Mixing ratio: Main agent vs. hardener = I Mixing ratio: Main agent vs. hardener
4:1 = 10:1
I Viscosity: 10 — 13 sec/20°C (68°F) I Viscosity: 10 — 13 sec/20°C (68°F)
I Film thickness: 35 — 45µ I Film thickness: 15 — 20µ
I Spraying pressure: 245 — 343 kPa (2.5 I Spraying pressure: 245 — 343 kPa
— 3.5 kg/cm2, 36 — 50 psi) (2.5 — 3.5 kg/cm2, 36 — 50 psi)
7 Drying Not required. Dry at normal temperature [10 min. or
more at 20°C (68°F)]. In half-dried
condition, avoid dust, dirt.
8 Top coat paint (II) Not required. Apply a clear coat to parts with top coat
paint (I), three times, at 5 — 7 minute
intervals.
I Paint in use
Metallic paint
Hardener PB
Thinner T-301
I Mixing ratio: Clear vs. hardener = 6:1
I Viscosity: 14 — 16 sec/20°C (68°F)
I Film thickness: 25 — 30µ
I Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
9 Drying 60°C (140°F), 60 min. or 80°C (176°F), 30 min. If higher than 80°C (176°F), PP may
be deformed. Keep maximum temperature of 80°C (176°F).
10 Inspection Paint check.
11 Masking removal Remove masking in process No. 2.
43
5-1 [W700] SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper

All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be
restored to its former condition. Damage limited to shallow scratches that cause only a change in the lus-
tre of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain
this point to the customer and get an understanding about the matter. Repair methods are outlined below,
based on a classification of the extent of damage.
A: MINOR DAMAGE CAUSING ONLY A CHANGE IN THE LUSTRE OF THE

BUMPER DUE TO A LIGHT TOUCH
Almost restorable.
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the repairing area with #500 sandpaper in a “feathering” motion.
3 Finish Resin section Coated section
Repeatedly apply wax to the affected Perform either the same operation as for
area using a soft cloth (such as flan- the resin section or process No. 18 and
nel). subsequent operations in the “(3)”
Recommended wax: NITTO KASEI section, depending on the degree and
Soft 99 TIRE WAX BLACK, or equiva- nature of damage.
lent.
Polish the waxed area with a clean
cloth after 5 to 10 minutes.
B: DEEP DAMAGE CAUSED BY SCRATCHING FENCES, ETC.

A dent cannot be repaired but a whitened or swelled part can be removed.
1 Cleaning Clean damaged area with water.
2 Removal of damaged Cut off protruding area, if any, due to collision, using a putty knife.
area
3 Sanding Grind the affected area with #100 to #500 sandpaper.
4 Finish Resin section Coated section
Same as Process No. 3 in the “(1)” Perform Process No. 12 and subsequent
section. operations in the “(3)” section.
C: DEEP DAMAGE SUCH AS A BREAK OR HOLE THAT REQUIRES FILLING

Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not
really worth the expense. (The surface, however, will become almost flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)
Process Process name Job contents
No.
1 Job contents Remove bumper as required.
2 Part removal Remove parts built into bumper as required.
3 Bumper placement Place bumper on a paint worktable as
required. It is recommended that con-
tour of worktable accommodate internal
shape of bumper.
G5M0164
4 Surface preparation Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suit-
able solvent (NRM No. 900 Precleno, white gasoline, or alcohol).
44
SERVICE PROCEDURE [W7C0] 5-1

No.
5 Cutting If nature of damage is cracks or holes,
cut a guide slit of 20 to 30 mm (0.79 to
1.18 in) in length along the crack or
hole up to the bumper’s base surface.
Then, bevel or “vee-out” the affected
area using a knife or grinder.
G5M0165
6 Sanding (I) Grind beveled surface with sandpaper (#40 to #60) to smooth finish.
7 Cleaning Clean the sanded surface with the same solvent as used in Process No. 4.
8 Temporary welding Grind the side just opposite the beveled area with sandpaper (#40 to #60) and clean
using a solvent. Temporarily spot-weld the side, using a PP welding rod and heater
gun.
G5M0166
NOTE:
I Do not melt welding rod until it flows out. This results in reduced strength.
I Leave the welded spot unattended until it cools completely.
9 Welding Using a heater gun and PP welding rod, weld the beveled spot while melting the rod
and damaged area.
G5M0167
NOTE:
I Melt the sections indicated by hatched area.
I Do not melt welding rod until it flows out, in order to provide strength.
I Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
I Leave the welded spot unattended until it cools completely.
45
5-1 [W7C0] SERVICE PROCEDURE

No.
10 Sanding (II) Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead
of the knife, operate it at a rate lower than 1,500 rpm and grind the excess part little by
little. A higher rpm will cause the PP substrate to melt from the heat.
G5M0168
Sand the welded spot smooth with #240 sand paper.
11 Masking Mask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
12 Cleaning/ degreasing Completely clean the entire coated area, using solvent similar to that used in Process
No. 4.
13 Primer coating Apply a coat of primer to the repaired surface and its surrounding areas. Mask these
areas, if necessary.
Recommended primer: Mp/ 364 PP Primer
NOTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa (2.5 to
3.5 kg/cm2, 36 to 50 psi) with a spray gun.
14 Leave unattended. Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is
half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended
with alcohol. (Do not use thinner since the coated area tends to melt.)
15 Primer surfacer coating Apply a coat of primer surfacer to the repaired area two or three times at an interval of
3 to 5 minutes.
Recommended surfacer:
I UPS 300 Flex Primer
I No. 303 UPS 300 Exclusive hardener
I NPS 725 Exclusive Reducer (thinner)
I Mixing ratio: 2 : 1 (UPS 300: No. 303)
I Coated film thickness: 40 — 50µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C
(140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sandpaper and water.
18 Cleaning/ degreasing Same as Process No. 12.
19 Top coat (I) Solid color Metallic color
Use a “block” coating method. Use a “block” coating method.
I Recommended paint: I Recommended paint:
Suncryl (SC) Suncryl (SC)
No. 307 Flex Hardener No. 307 Flex Hardener
SC Reducer (thinner) SC Reducer (thinner)
I Mixing ratio: 3 : 1 I Mixing ratio: 3 : 1
(Suncryl: No. 307) (Suncryl: No. 307)
I Viscosity: 11 — 13 sec/20°C (68°F) I Viscosity: 11 — 13 sec/20°C (68°F)
I Coated film thickness: 40 — 50µ I Coated film thickness: 20 — 30µ
I Spraying thickness: 245 — 343 kPa I Spraying thickness: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi) (2.5 — 3.5 kg/cm2, 36 — 50 psi)
20 Leave unattended. Not required. Leave unattended at 20°C (68°F) for at least
10 minutes until the topcoated area is half-
dry.
NOTE:
Be careful to keep dust or dirt from coming in
contact with the affected area.
46

No.
21 Top coat (II) Not required. Apply a clear coat three times at an interval
of 3 to 5 minutes.
I Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
I Mixing ratio: 3 : 1
(SC710: No. 307)
I Coated film thickness: 20 — 30µ
I Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
22 Drying Allow the coated surface to dry at 20°C (68°F) for two hours or 60°C (140°F) for 30
minutes.
NOTE:
Do not allow the temperature to exceed 80°C (176°F) since this will deform the PP
substrate.
23 Inspection Carefully check the condition of the repaired area.
24 Masking removal Remove masking tape applied in Process No. 11 and 13.
25 Parts installation Install parts on bumper in reverse order of removal.
26 Bumper installation Install bumper.
47
8. Side Protector
8. Side Protector NOTE:

I Type A: Insert clip pins into holes in body, then
A: REMOVAL AND INSTALLATION fit end cap buffers into place.
I Type B: Insert spin weld clips into holes in body,
NOTE: then fit bushings into place.
Do not re-use protector. I Type C and D: Align the clips with holes in body
1) Type A and B: and insert them.
Protector is attached to body with clips. I Install clips in standard holes first.
While holding end of protector by hand, force pro-
tector out.
H5M0718A
G5M0170
2) Type C:
Protector is attached to body with clips.
Remove door inner trim, and detach protector by
pushing clip pawl from inside.
3) Type D:
Protector is attached to body with clips.
While holding end of protector by hand, force pro-
tector out.
G5M0171
48
9. Front Fender
9. Front Fender NOTE:

Check for alignment of front fender with hood and
A: REMOVAL AND INSTALLATION front door with front fender at all points. Adjust, if
necessary.
1) Disconnect ground cable from battery.
2) Remove mud guard.
3) Remove parking light and headlight.
4) Remove front bumper.
5) Remove bolts which secure fender to radiator
panel and turn signal light connector.
G5M0175
G5M0174
G5M0176
G5M0115
6) Remove body protector. (This step may be

skipped if fender is to be reused.)
7) Remove attaching bolt to remove fender.
CAUTION:
Be careful not to scratch body panels with
fender edges when removing it.
49
10. Mud Guard and Rear Arch Protector
10. Mud Guard and Rear Arch 11. Cowl Panel

Protector A: REMOVAL AND INSTALLATION
A: REMOVAL AND INSTALLATION 1) Remove wiper arms.
2) Open front hood.
1. MUD GUARD
3) Pry clip off front hood seal using a screwdriver.
1) Jack-up vehicle to remove tire. 4) Lift cowl panel and remove clips from wind-
2) Remove screws and clips. Move mud guard shield.
toward the center of the body and remove mud
guard.
G5M0544
G5M0177
NOTE:
Install middle clip and other clips in that order.
CAUTION:
Only use new nuts and clips.
2. REAR ARCH PROTECTOR
1) Remove clip and screws.
G5M0545
G5M0178
2) Remove arch protectors.

CAUTION:
Only use new nuts and clips.
50
13. Front Grille
12. Molding and Retainer 13. Front Grille

1) Remove weatherstrip. 1) Remove two upper clips from body panel. To
2) Remove tapping screws. facilitate removal, press portion shown in figure
using screwdriver while lightly pulling front grille.
G5M0181
H5M0719A
NOTE: 2) Installation is in the reverse order of removal.
Insert clips onto hooks, then fasten with screws. NOTE:
Attach all clips to grille. Align them with clip hole in
body and push them into place.
G5M0182
51
14. Sunroof
14. Sunroof 5) Close sunroof and remove nuts.
A: REMOVAL
1. SUNROOF PANEL
1) Open sunroof approx. 1/3.
2) Remove clips attached to front side of sunroof
trim by pulling trim from inside of compartment.
G5M0188
6) Remove sunroof panel.

NOTE:
Sunroof trim reference pin must be fitted in holder
notch.
G5M0185
2. SUNROOF MOTOR AND RELAY
3) Move trim forward, and detach trim end from 1) Remove roof trim, rear quarter trim, pillar trim,
holder. etc.
<Ref. to 5-3 [W500].>
2) Remove screw.
3) Disconnect connector.
G5M0186
4) Detach trim.
G5M0190
4) Remove relay by pulling it out.

3. SUNROOF FRAME
1) Remove roof trim, rear quarter trim, pillar trim,
etc.
<Ref. to 5-3 [W500].>
2) Remove sunroof panel.
3) Disconnect front and rear drain tubes.
G5M0187
G5M0193
52
14. Sunroof
4) Disconnect connector between body harness B: INSTALLATION

and sunroof harness.
1) Insert frame rear end slit to two bolts fitted tem-
porarily to roof brace.
G5M0194
5) Loosen two mounting bolts near motor. (Do not G5M0198

remove bolts.)
2) Align frame to reference pin installed on roof.
G5M0195
G5M0199
6) Remove six bolts, and four adjusting nuts.
3) Tighten adjusting nut (that is, set frame at high-
est position).
Temporarily tighten bolts.
G5M0196
7) Remove sunroof frame.

8) Loosen set bracket mounting bolt. G5M0200
4) Install sunroof panel.
G5M0197
53
14. Sunroof
5) Adjust height by turning adjusting nut. 8) Install drain tubes.

Also adjust front, rear, right, and left side partitions. CAUTION:
Partition clearance: Insert drain tube securely into drain pipe.
5.9±0.5 mm (0.232±0.020 in) Length: A
Approx. 20 mm (0.79 in)
G5M0201
G5M0205
Difference in height between roof panel and
sunroof panel: 9) Install roof trim.
0±1.0 mm (0±0.039 in) 10) Install garnish.
NOTE:
Place garnish joint at rear center of body.
G5M0202
6) Tighten set bracket mounting bolts.

G5M0206
11) Install sunroof trim, pillar trim, rear quarter trim

etc.
12) Check the following items after assembling all
parts;
(1) Garnish must be free from waves.
(2) When sunroof is fully closed, must be no
clearance between garnish and sunroof trim.
(3) Sunroof must be free from slack and noise
when it is fully opened and closed.
G5M0203
7) Tighten bolts.
G5M0204
54
16. Hood Duct
15. Rear Spoiler 16. Hood Duct

1. COUPE 1. CENTER DUCT
1) Remove stoppers from both sides of trunk lid. 1) Open the hood.
2) Remove clip and screws, then remove brace
cover.
G5M0616
2) Disconnect high-mount stop light connector.

H5M0930
3) Remove six nuts.

4) Disconnect the two clips from hood, then
remove hood duct grille.
G5M0617
3) Remove nuts from rear spoiler.

CAUTION:
Be careful not to drop nuts into box section of
H5M0747A
trunk lid.
2. SIDE DUCT
1) Open the hood.
2) Remove four nuts.
3) Disconnect the two clips from brace cover, then
remove brace cover.
H5M0673A
4) Lift rear spoiler and unfasten clips.

5) Remove spoiler from trunk lid.
CAUTION:
Be careful not to damage trunk lid.
Tightening torque: H5M0748A
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
4) Remove duct grille.
55
5-1 [K100] DIAGNOSTICS
1. Sunroof
1. Sunroof
Entry of water into compartment (1) Check roof panel and sunroof panel for improper or poor sealing.
(2) Check drain tube for clogging.
(3) Check sunroof frame seal and body for improper fit.
Booming noise (1) Check roof panel and roof panel for improper clearance.
(2) Check sunroof trim and roof trim for improper clearance.
Abnormal motor noise (1) Check motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cable for wear.
(4) Check cable pipe for deformities.
Failure of sunroof to operate (Motor operates properly.) (1) Check guide rail for foreign particles.
(2) Check guide rail for improper installation.
(3) Check parts for mutual interference.
(4) Check cable slider for improper clinching.
(5) Check cable for improper installation.
(6) Check clutch adjustment nut for improper tightness.
Motor does not rotate or rotates improperly. (Use sun- (1) Check fuse for blowout.
roof wrench to check operation.) (2) Check switch for improper function.
(3) Check motor for incorrect terminal voltage.
(4) Check relay for improper operation.
(5) Check poor grounding system.
(6) Check cords for discontinuity and terminals for poor connections.
(7) Check limit switch for improper operation.
56
1. Door Alignment
1. Door Alignment
A: SEDAN AND WAGON MODEL
G5M0485
2
SPECIFICATIONS AND SERVICE DATA [S1B0] 5-2
1. Door Alignment
B: COUPE MODEL
G5M0637
3
1. Front Door
1. Front Door
H5M0903A
(1) Gusset (8) Checker Tightening torque: N·m (kg-m, ft-lb)

(2) Weatherstrip (9) Guide
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Stabilizer (Outer) (10) Sealing cover
T2: 13±3 (1.3±0.3, 9.4±2.2)
(4) Stabilizer (Inner) (11) Door panel
T3: 25±3 (2.5±0.3, 18.1±2.2)
(5) Protector (12) Lower hinge
(6) Stopper (13) Upper hinge T4: 29±5 (3.0±0.5, 21.7±3.6)
(7) Knock pin
4
2. Rear Door
2. Rear Door
H5M0904A
(1) Weatherstrip (7) Seating cover Tightening torque: N·m (kg-m, ft-lb)
(2) Stabilizer (Outer) (8) Door panel
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Stabilizer (Inner) (9) Lower hinge
T2: 25±3 (2.5±0.3, 18.1±2.2)
(4) Stopper (10) Upper hinge
T3: 29±5 (3.0±0.5, 21.7±3.6)
(5) Knock pin
(6) Checker
5
3. Fixed Glass
3. Fixed Glass
H5M0698C
(1) Windshield glass (4) Molding (7) Rear quarter glass (Coupe)
(2) Dam rubber (5) Rear window glass (8) Fastener
(3) Locate pin (6) Rear quarter glass (Wagon)
6
4. Front Door Glass
4. Front Door Glass
H5M0905A
(1) Door sash (Front) (6) Regulator handle Tightening torque: N·m (kg-m, ft-lb)
(2) Glass (Except power window)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Door sash (Rear) (7) Retainer spring
T2: 14±4 (1.4±0.4, 10.1±2.9)
(4) Weatherstrip (Inner) (8) Regulator ASSY
(5) Regulator and motor ASSY
7
5. Rear Door Glass
5. Rear Door Glass
H5M0906A
(1) Door sash (Front) (6) Regulator handle Tightening torque: N·m (kg-m, ft-lb)
(2) Glass (Except power window)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Weatherstrip (Inner) (7) Retainer spring
T2: 14±4 (1.4±0.4, 10.1±2.9)
(4) Door sash (Rear) (8) Regulator ASSY
(5) Regulator and motor ASSY
8
6. Rear Gate and Glass
6. Rear Gate and Glass
H5M0907A
(1) Rear gate (8) Glass pin (15) Hinge

(2) Clip (9) Trim
(3) Key cylinder (10) Glass Tightening torque: N·m (kg-m, ft-lb)
(4) Outer handle (11) Buffer T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(5) Auto-door lock actuator (12) Rear gate side buffer T2: 14±4 (1.4±0.4, 10.1±2.9)
(6) Striker (13) Stud T3: 25±5 (2.5±0.5, 18.1±3.6)
(7) Latch (14) Gas stay
9
5-2 [C7A0] COMPONENT PARTS
7. Door Lock Assembly

A: FRONT DOOR
H5M0908A
(1) Cover (6) Switch ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Inner remote ASSY (7) Auto-door lock actuator
T1: 6.4±2.0 (0.65±0.2, 4.7±1.4)
(3) Door outer handle
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(4) Striker
T3: 14±4 (1.4±0.4, 10.1±2.9)
(5) Door latch
10
COMPONENT PARTS [C7B0] 5-2
B: REAR DOOR
H5M0909A
(1) Door outer handle (6) Cover Tightening torque: N·m (kg-m, ft-lb)
(2) Door latch (7) Inner remote ASSY
T1: 6.4±2.0 (0.65±0.2, 4.7±1.4)
(3) Auto-door lock actuator
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(4) Striker
T3: 14±4 (1.4±0.4, 10.1±2.9)
(5) Rod holder
11
8. Door Trim
8. Door Trim
H5M0928A
(1) Trim panel (Coupe) (4) Gusset cover (7) Weatherstrip

(2) Trim panel (Except coupe/front) (5) Bracket
(3) Trim panel (Except coupe/rear) (6) Cover
12
9. Weatherstrip
9. Weatherstrip
H5M0700B
(1) Rear gate weatherstrip (3) Upper and side weatherstrip (6) Weatherstrip (Front door)
(Wagon only) (4) Retainer (Center)
(2) Retainer and molding (5) Weatherstrip (Rear door)
13
5-2 [W100] SERVICE PROCEDURE
1. Procedure Chart for Removing and Installing Door and Related Parts
1. Procedure Chart for Removing and Installing Door and Related

Parts
NOTE:
This flowchart shows the main procedures for removing and installing the door and its related parts. For
details, refer to the text.
H5M0910A
14
2. Door
2. Door 2. TRIM PANEL

1) Press retainer spring (A) with a thin flat-bladed
A: REMOVAL AND INSTALLATION screwdriver and then remove regulator handle (B).
1. DOOR ASSEMBLY (models without power window)
1) Remove lower trim and disconnect connectors
from body harness.
2) Place a cloth or a wood block under door to
prevent damage, and support it with a jack.
3) Remove checker pin by driving it upward. Be
careful not to damage door and body.
B5M0329C
2) Using ST, disengage the clip.

ST 925580000 PULLER
G5M0486
4) Remove bolts (M8) securing upper and lower

hinges to door, and remove door from hinges.
Tightening torque:
25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
5) Remove hinges by loosening hinges mounting
bolt (M8) off of body. G5M0390
Tightening torque:
29±5 N·m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
CAUTION:
Work carefully to avoid damaging door.
G5M0385

NOTE:
Apply grease to moving parts of door hinges.
15
2. Door
3) Remove gusset cover (C) and screws. I When repairing or replacing sealing cover, use
4) Remove trim panel and then disconnect con- “CEMEDINE 5430L” as sealer. It may be overlaid
nector. (models with power window) on existing sealer.
CAUTION: Sealer:
Be careful not to break clip by applying undue CEMEDINE 5430L
force. CAUTION:
I Any breaks in sealer can cause water leak-
age or entry of air and dust. Be sure sealer is
applied in a continuous line.
I Make sure sealing cover bonded areas are
free from wrinkles or openings.
4. CHECKER
1) Remove trim panel.
2) Remove sealing cover.
3) Apply a cloth to door and body to prevent dam-
aging them, and remove checker pin by driving it
upward.
CAUTION:
Be careful not to damage door and body.
H5M0929A

3. SEALING COVER G5M0392
1) Remove trim panel. 4) Completely close door glass.

2) Remove speaker, trim bracket and remote 5) Loosen two nuts securing checker, and take out
assembly and disconnect connectors. checker through access hole in underside.
3) Remove sealer with a spatula. 6) Installation should be made in the reverse order
of removal.
CAUTION:
Be careful because cover may break if sealer is Tightening torque:
removed forcefully. 7.5±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
5. INNER REMOTE
3) Disconnect joints of two rods.
G5M0391

NOTE:
I Confirm that sealer is properly applied without G5M0394
breaks. Then install sealing cover.
16
2. Door
4) Unlatch rod holder. 6) Loosen screws securing both latch and

5) Remove screws holding remote assembly. actuator, then remove latch and actuator assembly
through service hole in bottom.
G5M0395
G5M0396
NOTE:
If rear door is equipped with child safety lock, Tightening torque (screw):
check that child lock lever moves without dragging. 6.4±2.0 N·m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
NOTE:
6. DOOR LATCH
I Check operation of each part.
1) Remove trim panel. I Check each sliding part for proper lubrication.
2) Remove inner remote assembly. CAUTION:
3) Remove sealing cover around latch service After installation, be sure lock mechanism
hole. operates normally.
4) Completely close door glass.
5) Remove latch and actuator assembly: 7. OUTER HANDLE
(1) Turn rod holder to disconnect joint between 1) Remove trim panel.
key lock and rod. 2) Remove sealing cover.
(2) Turn rod holder to disconnect joint between 3) Detach door latch rod from outer handle and
outer handle and rod. key lock.
(3) Turn rod holder to disconnect joint between 4) Loosen nut securing outer handle and then
crank and rod. remove outer handle from outside.
CAUTION:
Be careful not to damage door.
G5M0397
G5M0398

Tightening torque:
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
17
2. Door
8. KEY LOCK B: ADJUSTMENT

1) Remove trim panel. 1. DOOR ASSEMBLY
1) Using ST, loosen bolts securing upper and
3) Completely close door glass. lower hinges to body, and adjust fore-and-aft and
4) Remove outer handle. vertical alignment of door.
5) Loosen spring securing key lock. ST 925610000 DOOR HINGE WRENCH
6) Remove key lock from outer handle.
NOTE:
Install so that key slot in key lock comes to center
of hole in outer handle.
9. GUSSET
1) Be sure window is all the way down.
2) Remove gusset cover.
G5M0487
4) Remove door rearview mirror.
5) Remove outer weatherstrip. 2) Loosen screw one complete rotation, and
6) Remove sealing cover. adjust opening/closing direction of door using a
hammer covered with a cloth.
NOTE:
Be careful not to drop nuts on the “IN” side. CAUTION:
Be careful not to damage striker.
7) Remove bolts and nuts which secure gusset.
Hinge tightening torque (body side):
Tightening torque: Bolt 29±5 N·m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
3±3 N·m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
Striker tightening torque:
Tightening torque: Nut 14±4 N·m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb) 2. INNER REMOTE
1) Lock the door.
2) Loosen bolt (A).
3) Lower bell crank (B) and then tighten bolt (A).
G5M0399
8) Lift out gusset.

H5M0911A
18
2. Door
3. PROCEDURE CHART FOR ADJUSTING DOOR GLASS
H5M0912A
19
2. Door
4. FRONT DOOR GLASS
H5M0697B
20
2. Door
H5M0728B
21
2. Door
I Door glass fit adjustment 2) Make sure of unequal dimensions.

Before adjusting door glass alignment, ensure
adjusting bolts for stabilizers, upper stoppers and
sashes are loose and glass is raised so that it is in
contact with upper and side weatherstrip.
1) Temporarily tighten one of the two rear sash
adjusting bolts, at midpoint of oblong hole on inner
panel.
2) Temporarily tighten regulator B channel at a
position slightly lower than midpoint of oblong hole
on inner panel.
3) Lower door glass 10 to 15 mm (0.39 to 0.59 in)
from fully closed position. While applying outward
pressure (load) to upper edge of glass above mid-
point of two outer stabilizers, press inner stabilizer
until it just touches the glass, then secure it.
Load: F
Front door glass 44.1±4.9 N (4.5±0.5 kg,
9.9±1.1 lb)
Rear door glass 44.1±4.9 N (4.5±0.5 kg,
9.9±1.1 lb)
G5M0639
3) If glass tilts to far rearward, loosen adjusting nut

(C) and adjust glass to be parallel with center pillar,
then after adjustment, tighten adjusting nut (C).
Tightening torque:
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
G5M0421
I Remedy for unequal dimensions,

between upper, lower and center pillar
sides
1) Close front door and raise door glass.
H5M0687A
H5M0689A
22
2. Door
I Remedy for improper glass to center I Remedy for improper upper stop point
pillar clearance of door glass
1) Close front door and raise door glass. 1) Loosen front and rear sash stoppers.
2) Make sure of improper clearance. 2) Increase the upward travel of window glass up
to the position where upper edge just touches
weatherstrip surface with door closed.
H5M0688A
G5M0511
3) After adjustment, temporarily tighten stoppers.

NOTE:
Make sure that each glass stopper is touched.
I Remedy for incorrect contact of door
glass to weatherstrip
1) Close front door and raise door glass.
2) If clearance is below specifications, loosen bolt
H5M0690A (A) and bolt (B).
3) If clearance is over specifications, tighten bolt
3) If clearance is improper, loosen adjusting nut
(A) and bolt (B).
(A), bolt (A) and adjust glass to center pillar.
H5M0693A
H5M0692B
H5M0691A
23
2. Door
I Fit adjustment 2) Adjust front sash fit using rear sash adjustment
Door glass fit is adjusted by displacing the glass procedure outlined in the former procedure as a
front edge with a stabilizer. guide. Two adjusting bolts must be adjusted by the
same amount.
NOTE:
Before adjusting glass fit, visually check to deter- NOTE:
mine relative adjusting positions of retainer and I Front and rear sash adjustment procedures are
molding (on roof side) and glass surface. basically the same; however, the amount of adjust-
ment is not always the same due to alignment dis-
1) Alternately adjust two rear sash adjusting bolts persion of individual doors.
(A) until dimensions are obtained.
I Adjust front and rear sash fit, as equally as pos-
CAUTION: sible. Otherwise, effort required to operate regula-
Do not loosen two adjusting nuts (A) at the tor may increase.
same time, as this moves sash fore and aft,
creating unequal glass- to-sash clearance. Dur- 3) After adjusting front sash-to-glass fit, secure
ing adjustment, loosen only one nut and keep front sash.
the other tightened.
H5M0693A
NOTE:
Always adjust two rear sash adjusting bolts (A) by
the same amount. Do not adjust the adjusting bolts
with sash bracket inclined toward inner panel, as
this increases effort required to operate regulator.
G5M0510
24
2. Door
5. REAR DOOR GLASS

Alignment of rear door glass is basically the same as for the front door glass. Due to slight difference in
adjustment dimensions for fore-aft, up-down, and in-out alignments, key points for rear door adjustment are
described.
H5M0913A
25
2. Door
I Fore-aft adjustment I Fit adjustment

1) Door glass alignment must be adjusted so that Increasing contact pressure causes rear door
glass-to-center pillar fit is equal at all points. glass to be caught in center pillar upper and lower
Always use dimensions as a guide during adjust- weatherstrip; this will cause premature weather-
ment. strip wear. For this reason, always use dimensions
NOTE: indicated in figure as a guide during glass fit adjust-
If dimensions are smaller than those indicated, ment.
glass will be caught in weatherstrip and may not
raise to the fully closed position.
H5M0693A
G5M0472
2) After making fore-aft adjustment, raise and

lower glass to ensure it is free from any binding.
C: INSPECTION
1. FRONT DOOR GLASS
1) Close front door and make sure of all clearances.
H5M0695A
H5M0696A
2) If any clearance is not correct, adjust affected CAUTION:

parts. Re-check that all clearances are correct. I Repeatedly adjust parts until all clearances
are correct.
I After clearance adjustment, make sure that
all adjusting bolts and nuts are tightened.
26
2. Door
2. REAR DOOR GLASS

1) Close rear door and make sure of all clearances.
G5M0474
2) If any clearance is not correct, adjust affected

parts. Re-check that all clearances are correct.
CAUTION:
I Repeatedly adjust parts until all clearances
are correct.
I After clearance adjustment, make sure that
all adjusting bolts and nuts are tightened.
27
3. Rear Gate
3. Rear Gate (2) Remove bolts which hold gas stay to rear
gate.
A: REMOVAL AND INSTALLATION CAUTION:
CAUTION: I Be careful because rear gate drops while
I Be careful not to scratch coated surfaces of removing bolts. Have an assistant support it
vehicle body and window glass during while removing bolts.
removal. Place a cloth over the affected area. I Be sure to place a folded cloth between rear
I Be careful not to damage trim panels. gate and body to prevent scratches.
I Use an assistant when handling heavy parts.
I Be careful not to damage or lose small parts.
1. REAR GATE ASSEMBLY
1) Remove clips from trim panel and detach trim
panel.
CAUTION:
Be careful not to damage clips or their holes.
G5M0402
9) Remove the bolts which hold rear gate to hinge

and then detach rear gate.
G5M0400
2) Disconnect connectors and terminal.

3) Disconnect rear washer hose from wiper motor.
4) Remove high-mounted stop light.
5) If disconnected harness is re-used, tie connec- G5M0403
tor with a string and place on the upper side of rear
gate for ready use. 10) General precautions in handling rear gate gas
CAUTION: stay
Do not forcefully pull cords, lead wires, etc. CAUTION:
since damage may result; carefully extract I Do not attempt to disassemble gas stay
them in a wavy motion while holding connec- because its cylinder is filled with gas.
tors. I Before discarding gas stay, place it at a
slight angle with the cylinder body side facing
up and drill a 2 to 3 mm (0.08 to 0.12 in) dia.
hole to completely discharge the content. (Gas
is odorless, colorless and harmless; however,
metal powder may come out of the hole.)
G5M0401
6) Remove rear wiper. <Ref. to 6-2 [W600].>

7) Remove both rubber ducts and then extract
washer hose and harness connector.
8) Gas stay: G5M0490
(1) Completely open rear gate.
28
3. Rear Gate
I It is good practice to place a vinyl sack over 3. OUTER HANDLE

it before drilling the hole because oil may spurt
out. Be careful to prevent vinyl cover from
becoming entangled on the drill. 2) Remove latch.
3) Remove two nuts used to hold outer handle to
the inside of rear gate, and detach outer handle.
CAUTION:
Be careful not to damage packing when remov-
ing outer handle.
G5M0491
I Be careful not to scratch the exposed sec-

tion of piston rod or allow oil or paint to come
in contact with it.
I Do not attempt to rotate the extended piston
G5M0405
rod.
11) Installation is in the reverse order of removal. 4) Installation is in the reverse order of removal.
CAUTION: CAUTION:
I Be careful not to mistake RH and LH body Completely insert latch pin into handle lever.
side buffers.
I Be sure to add sealer to hinge. 4. KEY CYLINDER
I When installing rear gate, be careful not to 1) Remove trim panel.
damage coating on body and rear gate. 2) Disengage rod from holder.
2. LATCH 3) Remove retaining spring from key cylinder, and
detach key cylinder from outside.
1) Remove trim panel. 4) Installation is in the reverse order of removal.
2) Disengage rod from holder (= key cylinder).
3) Remove bolts from auto-door lock actuator. 5. STRIKER
4) Remove bolts from latch, and detach latch.
1) Remove rear skirt trim.
2) Remove two bolts from striker and detach
striker.
G5M0404
5) Disconnect rear gate switch connector.

6) Disconnect auto-door lock actuator connector. G5M0406
7) Detach latch.
8) Installation is in the reverse order of removal. 3) Installation is in the reverse order of removal.
CAUTION:
Firmly join latch with key cylinder, and outer
handle.
29
3. Rear Gate
6. WEATHERSTRIP 2) Tap along entire length with a rubber hammer to

1) Place weatherstrip so that its joints meet at firmly insert body flange into weatherstrip.
lower center of vehicle body, and install by insert- CAUTION:
ing flanged portion from below, as shown in section I Be careful not to install in wrong direction.
A—A in figure. I Install weatherstrip carefully and firmly.
G5M0492 G5M0493
30
4. Procedure Chart for Removal and Installing Window Glass
4. Procedure Chart for Removal and Installing Window Glass

H5M0914A
1. MATERIALS REQUIRED FOR APPLICATION

Description Remarks
Repair adhesive set Sunstar No. 580 or Essex Chemical Corp’s Urethane E Sun-
I Cartridge of single-liquid urethane adhesive star No. 435-580
I Primer for glass and body
Windshield knife or piano wire For cutting windshield
Sealant gun For applying adhesive
Suction cups For holding glass
Putty knife For finishing adhesion surface and cutting spacer
Sponge For applying primer
Gauze or cloth For cleaning
Alcohol or white gasoline For cleaning adhesion surface
Tape For preventing damage to painted surface
31
5. Windshield
5. Windshield NOTE:
A matching pin is cemented to corners of glass on
A: REMOVAL compartment side. Use a piano wire when cutting
each pin.
1. USING WINDSHIELD KNIFE
The following procedure for the front windshield
can also be applied to other window glass.
1) Remove wiper arm and cowl panel.
2) Remove roof molding and front window molding
upper.
3) Remove glass:
(1) Put protective tape on body to prevent dam-
age.
(2) Apply soapy water to the surface of the
adhesive agent so the knife blade slides G5M0412
smoothly.
(3) Cut off excess adhesive agent. 2. USING PIANO WIRE
(4) Put windshield knife into layer of adhesive.
1) Remove wiper arm and cowl panel.
(5) Cut adhesive layer with the windshield
2) Remove roof molding and front window molding
knife.
upper.
CAUTION: 3) Remove glass:
I Keep knife edge along glass surface and end (1) Put protective tape on body to prevent dam-
face. age.
I When first putting knife into layer of (2) Using drill or putty knife, make through-hole
adhesive, select point with wide gap between (one place) in adhesive agent.
body and glass. (3) Pass piano wire through the hole from
inside the compartment, and connect both ends
of wire securely to wooden blocks.
G5M0494
(4) Cut adhesive layer with the wire by pulling

it back and forth.
CAUTION:
When making through-hole into adhesive layer
and cutting the adhesive, be careful not to
damage interior and exterior parts.
G5M0418
32
5. Windshield
B: INSTALLATION 6) Application of primer:

(1) Using a sponge, apply primer to part of
1) After cutting layer of adhesive, remove gum glass to be adhered.
rubber remaining on body. (2) Apply primer to part of body to be adhered.
2) Finishing adhesion surface on body side: Using
a cutter knife etc., cut layer of adhesive sticking CAUTION:
firmly to body, and finish it to a smooth surface of I Primer is hard to wipe off of body paint,
about 2 mm (0.08 in) in thickness. instrument panel, inner trim, etc. So put mask-
ing around these areas for protection.
CAUTION: I After application, let 1st primer dry sponta-
Take extra care not to cause damage to body neously for about 10 minutes.
paint. I Do not touch primer-coated surface under
any circumstances.
G5M0553
G5M0495
3) Cleaning body surface:
(1) Thoroughly remove chips, dirt and dust 7) Application of adhesive:
from body surface. (1) Cut nozzle tip of cartridge as shown in fig-
(2) Clean body wall surface and upper surface ure.
of layer of adhesive with a solvent such as alco-
hol or white gasoline.
4) Positioning glass:
(1) Mount glass on body.
(2) Adjust position of glass so that gap between
body and glass is uniform on all sides.
(3) Put matching pin on body and glass in sev-
eral places.
G5M0408
(2) Open cartridge and put it into a gun with

nozzle attached.
(3) Apply adhesive uniformly to all sides of
adhesion surface while operating gun along
glass end face.
8) Installation of glass:
G5M0407 (1) Hold glass with rubber suction cups.
5) Cleaning glass:
(1) Dismount glass from body.
(2) Clean surface of glass to be adhered with
alcohol or white gasoline.
33
5. Windshield
(2) Mount glass on body with matching pin CAUTION:

aligned. I Move vehicle very gently.
I Do not squirt strong hose stream on vehicle.
11) Spontaneous drying:
After completing all operations, leave vehicle alone
for 24 hours.
CAUTION:
When delivering vehicle to user, tell him that
vehicle should not be subjected to heavy
shocks for at least three days.
12) Install cowl panel and wiper arm.
G5M0409
(3) Stick them fast by pressing all sides lightly.

9) Installation of molding:
(1) Remove adhesive overflowing from outside
of glass until it becomes level with outer height
of glass. Then, add adhesive to portions that
need it, and clean with alcohol or white gaso-
line.
G5M0496
(2) Firstly, press-fit front window molding upper

and lastly, roof molding.
CAUTION:
Do not open and close door after moldings
have been installed. When opening and closing
door for unavoidable reason, lower door glass
and gently move door.
G5M0417
10) Water leakage test:

Test for water leakage about one hour after instal-
lation.
34
6. Rear Window Glass
6. Rear Window Glass 2. WAGON MODEL

NOTE:
A: REMOVAL It is impossible to remove the molding from the
1. SEDAN AND COUPE MODEL glass. If molding is broken, replace rear glass.
1) Remove roof molding. 1) Remove rear wiper and rear gate trim.
2) Remove rear window molding upper and lower. 2) Disconnect connector from rear defogger termi-
3) Disconnect connector from rear defogger terminal.
nal. 3) Remove high mount stop light.
4) Remove glass in same manner as in wind- 4) Remove glass in same manner as for wind-
shield. shield.
CAUTION:
Be careful not to damage molding re-installing
the old rear window glass using a piano wire.
NOTE:
A matching pin is cemented to corners of glass on
compartment side. Use a piano wire when cutting
each pin.
G5M0410
NOTE:
A matching pin is cemented to the corners of glass
on compartment side. Use a piano wire when cut-
ting each pin.
G5M0412
G5M0412
35
6. Rear Window Glass
B: INSTALLATION
1. SEDAN AND COUPE MODEL
1) Install glass in same manner as in windshield.
2) Firstly, press-fit molding upper, then lower and
lastly, roof molding.
G5M0411
3) After installation, test for water leakage after

about one hour, and leave vehicle alone for 24
hours.
4) Make rear defogger connections.
2. WAGON MODEL
1) Install rear gate trim.
2) Install glass in same manner as windshield.
G5M0413
3) About one hour after installation, test for water

leakage. Leave vehicle for 24 hours before using
it.
4) Connect rear defogger connections.
5) Install high mount stop light and rear wiper.
36
7. Rear Quarter Glass

A: REMOVAL
1. WAGON MODEL
1) Remove rear quarter molding on corner.
2) Remove glass in same manner as in wind-
shield.
G5M0416
2. COUPE MODEL
1) Remove rear quarter molding.
G5M0627
2) Remove glass in same manner as in wind-

shield.
G5M0628
37
B: INSTALLATION 5) Application of adhesive:

(1) Cut nozzle tip as shown in figure.
1. WAGON MODEL
1) Finish surface of adhesive layer on body: Using
a putty knife, etc., cut layer of adhesive stick firmly
to body and finish it into a smooth surface of about
2 mm (0.08 in) in thickness.
CAUTION:
Be careful not to damage body finish.
G5M0414

nozzle attached.
glass end face.
6) Installation of glass:
G5M0497 (1) Hold glass with rubber suction cups.
(2) Mount glass on body with matching pin
2) Cleaning of body surface:
aligned.
(1) Remove chips, dirt and dust from body sur-
face.
(2) Clean body wall surface and upper surface
of adhesive layer with a solvent such as alcohol
or white gasoline.
3) Cleaning glass:
(1) Remove dirt and dust from surface of glass
to be adhered.
4) Application of primer:
G5M0415
(1) Using a sponge, apply primer to surface of
glass to be adhered. (3) Stick them fast by pressing all sides lightly.
(2) Apply primer to surface of body to be 7) Water leakage test:
adhered. After installing glass, test for water leakage after
CAUTION: about one hour.
I If primer has dropped on body finish, it is CAUTION:
hard to wipe it off. So protect with masking. I Move vehicle slowly.
I Primer must not project from black frame of I When opening and closing door, lower door
glass. glass and move door gently.
I After applying primer, let it dry spontane-
ously for about 10 minutes.
for 24 hours.
CAUTION:
When delivering vehicle to user, tell him or her
that vehicle should not be subjected to heavy
G5M0495
38
2. COUPE MODEL 5) Application of adhesive:

1) Finish surface of adhesive layer on body: Using (1) Cut nozzle tip as shown in figure.
a putty knife, etc., cut layer of adhesive stick firmly
to body and finish it into a smooth surface of about
2 mm (0.08 in) in thickness.
CAUTION:
Be careful not to damage body finish.
G5M0629

nozzle attached.
G5M0497 glass end face.
2) Cleaning of body surface: 6) Installation of glass:
(1) Remove chips, dirt and dust from body sur- (1) Hold glass with rubber suction cups.
face. (2) Mount glass on body with matching pin
(2) Clean body wall surface and upper surface aligned.
of adhesive layer with a solvent such as alcohol
or white gasoline.
3) Cleaning glass:
(1) Remove dirt and dust from surface of glass
to be adhered.
4) Application of primer:
(1) Using a sponge, apply primer to surface of
glass to be adhered.
(2) Apply primer to surface of body to be G5M0630
adhered.
(3) Stick them fast by pressing all sides lightly.
CAUTION:
7) Water leakage test:
I If primer has dropped on body finish, it is
hard to wipe it off. So protect with masking. After installing glass, test for water leakage after
I Primer must not project from black frame of about one hour.
glass. CAUTION:
I After applying primer, let it dry spontane- I Move vehicle slowly.
ously for about 10 minutes. I When opening and closing door, lower door
glass and move door gently.
for 24 hours.
CAUTION:
When delivering vehicle to user, tell him or her
that vehicle should not be subjected to heavy
G5M0495
39
1. Door Glass
1. Door Glass
Condition Apparent cause/Correction
Glass in fully 1) Glass runs out of weatherstrip lip when considerable hand I Insufficient upward travel of glass
closed position pressure is applied to it from inside. Increase upward travel of glass.
G5M0502
(This condition may cause wind/booming noise during
high-speed operation.)
2) Clearance exists between glass and weatherstrip when light I Insufficient glass-to-door weatherstrip
hand pressure is applied to it at center and rear pillar locations. contact
Check stabilizer and glass for proper
contact.
Increase contact using upper sash
adjustment bolt.
I Insufficient glass-to-door weatherstrip
contact
Check stabilizer and glass for proper
contact.
Increase contact using upper sash
G5M0503 adjustment bolt.
(This condition may cause wind noise and/or water
leakage.)
3) Adjust door glass so that it is aligned with door rearview I Window is not properly adjusted in
mirror gusset up-down/fore-aft direction. Adjust win-
dow. If necessary, move “B” channel for
regulator to eliminate window “tilt”.
I Gusset is not properly adjusted in
fore-aft direction. Adjust gusset after
loosing all bolts and nuts witch tightening
it.
H5M0672A
40
DIAGNOSTICS [K100] 5-2
1. Door Glass

Door in fully 1) Glass rides over weatherstrip lip when door is closed. I Improper up-down and in-out glass
closed/ open alignments
position Adjust glass for up-down and in-out
alignments (incl. rear sash, upper stop-
per adjustment, etc.). If necessary, cor-
rect glass tilt by moving regulator “B”
channel.
G5M0505
(This condition increases wind/booming noise,
leakage and/or effort required to close door.)
2) Edge of glass contacts retainer when door is fully closed. I Improper glass-to-center pillar weath-
erstrip or excessive glass contact to
weatherstrip
Excessive adjusting in contact to weath-
erstrip causes rear edge of glass to tilt
inboard closer to center pillar. Adjust rear
sash adjustment bolt to reduce glass
contact to weatherstrip.
G5M0506
Raise or lower 1) Considerable effort or time is required to operate regulator. I Sliding resistance increased due to
window glass Standard operating effort: high stabilizer-to-glass contact pressure
I Entire up-down travel except for point 5 mm (0.20 in) below Reduce contact by mounting inner stabi-
fully closed position: 29.4 N (3.0 kg, 6.6 lb) lizer to inside of the car.
I Point 5 mm (0.20 in) below fully closed position: 45.0 N (4.5 I High glass-to-windshield contact pres-
kg, 10.12 lb) sure
Reduce contact using upper sash adjust-
ment bolt.
I Unequal contact adjustment stroke
between front and rear sashes
Set to equal stroke.
I Tilt of rear sash adjustment bolt
mounting bracket
Correct tilt of bracket so it is parallel to
inner panel.
G5M0507
41
1. Door Glass

Raise or lower 2) Center pillar weatherstrip is caught by rear window glass I Improper fore-aft or in-out alignment
window glass when glass is raised. of window glass
Lower regulator “B” channel to tilt win-
dow glass back.
G5M0508
3) Glass tilts forward by more than 2 mm (0.08 in). I Excessive glass contact pressure or
improper in-out alignment
1) Lower regulator “B” channel to tilt
glass rearward.
2) Reduce contact pressure using
upper sash adjustment bolt.
G5M0509
(Excessive tilt of glass forward is due to excessive
glass “contact” which causes reaction of center pillar weather-
strip.) Glass can be tilted forward due to increase in reaction of
shoulder weatherstrip or free play between sash and roller. Tak-
ing these symptoms into account, glass should be aligned.
42
3. Power Window
2. Door Lock System

No. Trouble Possible cause Remedy
Door cannot be opened by outer
1 handle. (Door can be opened by inner Disconnect outer handle rod. Connect firmly.
handle.)
Door cannot be opened by inner a. Joint of upper rod is disconnected.
Connect firmly. Functionally
2 handle. (Door can be opened by outer b. Rear door child lock lever is set to lock
normal.
handle.) side.
Connect firmly. Remove rod
Door does not open when outer or a. Joint of lower rod is disconnected.
from latch. Adjust rod so that
3 inner handle is operated with inner b. Lock is not released due to improper
lock knob is set in “lock” posi-
lock knob set to unlock position. adjustment of lower rod.
tion is locked.
Door opens even when inner lock a. Lower rod joint is separated.
Same as a in No. 3. Same as
4 knob is set to lock position. (Keyless b. Door is not locked due to improperly
a. in No. 3.
locking is impossible.) adjusted lower rod.
a. Inner handle fails to return completely.
5 Child lock lever will not come up. Refer to No. 6.
b. Joint of upper rod is disconnected.
Contact of upper rod with inner handle Eliminate contact by bending
6 Inner handle stops halfway.
mounting case. upper rod properly.
Door cannot be locked or unlocked by
7 Joint of key lock rod is disconnected. Connect firmly.
key.
Auto door-lock switch does not act Auto door-lock switch does not act due to
8 Same as a. in No. 3.
when inner lock knob is pushed. improperly adjusted lower rod.
3. Power Window
Symptom
All windows do not The window of driver The window of The window of
move. side does not move. driver side does each passenger
not move “AUTO” sides does not
down. move.
Battery (1)
Fuse in fuse box (2)
Circuit breaker and relay (3)
Main switch (4) (1) (1) (1)
Sub switch of each passenger sides (2)
Motor of driver side (2) (2)
Motor of each passenger sides (3)
Regulator assembly of each windows (4)
Power supply line of main switch (5) (3) (3)
Ground line (6)
Haness and connector (7) (4) (4) (5)
( ): Figures in a parenthesis refer to diagnostics procedures.
43
5-2 DIAGNOSTICS
MEMO:
44
1. Front Seat
1. Front Seat
H5M0701B
(1) Front seat ASSY (5) Outer slide rail ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Inner belt ASSY
T1: 23±5 (2.3±0.5, 16.6±3.6)
(3) Inner slide rail ASSY
T2: 29±7 (3.0±0.7, 21.7±5.1)
(4) Connect wire
T3: 52±10 (5.3±1.0, 38±7)
2
COMPONENT PARTS [C2A0] 5-3
2. Rear Seat
2. Rear Seat
A: SEDAN AND COUPE MODEL
H5M0915A
(1) Rear seat reinforcement (4) Rear cushion Tightening torque: N·m (kg-m, ft-lb)
(2) Hook
T1: 10±3 (1.0±0.3, 7.2±2.2)
(3) Backrest
T2: 25±7 (2.5±0.7, 18.1±5.1)
3
5-3 [C2B0] COMPONENT PARTS
2. Rear Seat
B: WAGON MODEL
H5M0916A
(1) Hinge bracket (RH) (8) Hinge Tightening torque: N·m (kg-m, ft-lb)
(2) Hinge bracket (RH) (9) Hinge cover
T1: 2±1 (0.2±0.1, 1.4±0.7)
(3) Backrest (LH) (10) Backrest center hinge
T2: 5.9±1.5 (0.6±0.15, 4.3±1.1)
(4) Striker (11) Belt pocket
T3: 10±3 (1.0±0.3, 7.2±2.2)
(5) Hinge bracket (LH) (12) Pad ASSY pocket
(6) Lock hinge (13) Hook T4: 25±7 (2.5±0.7, 18.1±5.1)
(7) Rear cushion
4
3. Front Seat Belt
3. Front Seat Belt
H5M0917A
(1) Adjuster anchor ASSY (5) Outer belt ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Through cover
T1: 13±3 (1.3±0.3, 9.4±2.2)
(3) Webbing guide
T2: 35±13 (3.6±1.3, 26±9)
(4) Inner belt ASSY
5
4. Rear Seat Belt
4. Rear Seat Belt
H5M0702B
(1) Webbing cover (RH) (6) Through cap (RH) Tightening torque: N·m (kg-m, ft-lb)
(2) Webbing cover (LH) (7) Through cap (LH)
T1: 13±3 (1.3±0.3, 9.4±2.2)
(3) Outer seat belt (LH) (8) Lap anchor cover (LH)
T2: 35±13 (3.6±1.3, 26±9)
(4) Center seat belt (9) Lap anchor cover (RH)
(5) Outer seat belt (RH)
6
5. Inner Accessories
5. Inner Accessories
H5M0918A
(1) Hook (3) Rearview mirror (5) Assist grip (retractable)

(2) Sun visor (4) Assist rail bracket (6) Assist grip (fixed)
7
6. Inner Trim
6. Inner Trim
H5M0703B
(1) Front pillar upper trim (9) Front pillar upper trim (17) Trim bracket
(2) Rear pillar upper trim (10) Rear quarter upper front trim (18) Rear quarter lower trim
(3) Rear pillar lower trim (11) Rear rail trim (19) Side sill rear upper cover
(4) Side sill rear upper cover (12) Rear quarter upper rear trim (20) Side sill rear lower cover
(5) Side sill rear lower cover (13) Rear gate trim (21) Center pillar lower trim
(6) Center pillar lower trim (14) Rear skirt trim (22) Side sill front lower cover
(7) Side sill front lower cover (15) Lamp cover (23) Front pillar lower trim
(8) Front pillar lower trim (16) Cover
8
1. Front Seat
1. Front Seat B: INSTALLATION

A: REMOVAL 1) While operating button (located on top of
backrest), lift headrest out by placing your hand
1) While operating button (located on top of between backrest and headrest.
backrest), lift headrest out with hand placed
between backrest and headrest.
H5M0704
H5M0704
2) Pull reclining lever back to fold backrest all the
way forward. Pull slide adjuster lever and move
2) Pull reclining lever back to fold backrest all the lower slide rail all the way backward.
way forward. While pulling slide adjuster lever, 3) Position seat in compartment and align the
move seat all the way forward. holes on the seat with the holes on the car body
3) Remove bolt cover at rear end of slide rail. side.
4) Remove bolts securing seat rear. 4) Secure the front of seat using inward and out-
ward bolts (A) and (B) in that order.
5) While pulling slide adjuster lever, move seat all
the way forward.
6) Secure the rear of seat using inward and out-
ward bolts (C) and (D).
S5M0366
5) While pulling slide adjuster lever, slide seat all

the way back.
6) Remove bolts securing front of seat.
H5M0706B
7) Connect connector under driver’s seat.

CAUTION:
Check that all lock plate pawls are completely
and equally inserted into the holes in the slide
rail brackets.
8) After installation, ensure that all mechanisms
operate properly and lock.
9) If any mechanism does not function properly,
G5M0344 loosen bolts (C) and (D), slide seat as required,
insert all lock plate pawls into holes in slide rail
7) Remove front seat from vehicle. brackets, and tighten bolts (C) and (D) in that
CAUTION: order.
Be careful not to scratch seat when removing 10) Install bolt cover on rear end of slide rail.
it from vehicle. 11) Install headrest on backrest.
NOTE:
Tighten bolts in the designated order.
9
2. Rear Seat
2. Rear Seat 4) Remove the bolt and then remove backrest (LH
side).
A: REMOVAL 5) Remove the bolt and then remove backrest (RH
side) from hinge bracket.
1. SEDAN AND COUPE MODEL
1) Remove bolts securing hinges (located at front
of cushion) to body.
2) Slightly raise front of cushion while pushing
down on cushion in the direction of “C”. With cush-
ion held in that position, move it forward until it is
unhooked.
B5M0333C
(A) Bolt (LH side)

(B) Bolt (Rh side)
(C) Hinge bracket
B: INSTALLATION
G5M0345 1. SEDAN AND COUPE MODEL
3) Remove bolts securing lower portion of back- 1) Before installing backrest, ensure that trim
rest to body. panel, insulator and seat belt are properly installed.
4) Lift rear seat backrest in direction “A” until it is 2) Transfer outer seat belt webbing to front of
released from upper hooks. backrest and fold backrest forward. Attach seat
belt webbing to upper hooks (2 places), and move
2. WAGON MODEL pillow in the direction of “B” until backrest is aligned
1) Remove bolts securing hinges (located at front with lower mounting holes in body.
of seat) to body.
G5M0348
G5M0350 3) Secure lower center and both sides of backrest

2) Pull strap (located in middle rear portion of to body with bolts.
cushion) to release lock. Lift cushion out and away
from body.
3) Pull knobs (located at each side of backrest’s
upper portion) up to release lock, and fold backrest
all the way forward.
10
2. Rear Seat
4) Slightly raise front section of cushion while 7) Install hinges to front of cushion and tighten
pushing down on cushion in the direction of “C”. with bolts. Check that lock properly engages.
With cushion held in that position, attach rear sec-
tion of cushion to hooks at lower frame location.
5) Secure front of cushion to body with bolts.
CAUTION:
I Before installing seat, ensure that seat belt is
placed on cushion.
I Confirm that winding of three-point type seat
belt can operate regularly.
G5M0353
8) Fold backrest onto cushion and overlap trunk

mat and mat at rear of backrest.
CAUTION:
I Do not allow center seat belt to get under
cushion when folding cushion.
I Ensure that side seat belt tongue is free from
cushion and trim panel.
G5M0345 I Lift front of cushion to ensure that cushion is
properly locked.
2. WAGON MODEL
1) Install hinge bracket to body.
2) Insert right backrest hinge pin into hole in
bracket. Tilt backrest backward until striker
engages with lock.
3) Secure right backrest center hinge to body
using a bolt.
G5M0352
4) Temporarily install left backrest side hinge to

body using a bolt, and fold backrest forward to the
floor.
5) Roll up mat (located at rear of left backrest),
and install center hinge using a bolt.
6) Tilt left backrest until striker engages with lock,
and tighten bolt.
11
3. Front Seat Belt
3. Front Seat Belt 2) Remove rear quarter trim.

WARNING:
Replace front seat belt worn by occupants of a
vehicle that has been in a serious accident. The
entire assembly should be replaced even if
damage is not obvious.
1. OUTER BELT (SEDAN AND WAGON)
1) Remove through-anchor cover cap.
G5M0640
2) Remove shoulder anchor bolt.
3) Remove webbing guide. 3) Remove webbing guide.
G5M0354
G5M0641
4) Remove center lower pillar trim panel.

5) Remove front cover side plate.
6) Roll up floor mat at the bottom of center pillar.
7) Remove lap anchor bolt.
G5M0653
4) Remove anchor cover cap.

5) Remove four bolts and then belt retractor and
G5M0355 outer belt. Tightening torque:
8) Remove belt retractor and outer belt.
9) Installation is in the reverse order of removal. Tightening torque:
T1: 13±3 N·m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
CAUTION: T2: 35±13 N·m (3.6±1.3 kg-m, 26±9 ft-lb)
I The left and right ELR’s are not mutually
interchangeable because different sensors are
used.
I Be careful not to twist belts during installa-
tion.
2. OUTER BELT (COUPE)
1) Remove rear seat cushion and backrest.
<Ref. to 5-3 [W2A1].>
G5M0642
12
4. Rear Seat Belt
CAUTION: 4. Rear Seat Belt

I The left and right ELR’s are not mutually
interchangeable because different sensors are A: REMOVAL AND INSTALLATION
used.
I Be careful not to twist belts during installa- WARNING:
tion. Replace rear seat belt worn by occupants of a
vehicle that has been in a serious accident. The
3. INNER BELT entire assembly should be replaced even if
1) Disconnect connector. damage is not obvious.
2) Remove anchor bolt and then detach inner belt. 1. SEDAN AND COUPE MODEL
1) Remove rear cushion from body.
2) Remove rear backrest from body.
3) Remove screw from lower side of rear quarter
trim, and lift-up lower side of rear quarter trim.
4) Remove trim panel rear bracket upper.
5) Remove rear quarter trim.
6) Remove outer anchor bolts.
S5M0234
4. ADJUSTABLE SHOULDER ANCHOR

1) Remove shoulder anchor bolt.
2) Remove lower center pillar trim.
3) Remove front and front pillar trim panel.
4) Remove adjustable shoulder anchor assembly.
G5M0358
7) Remove rear bolt from ELR.
G5M0357

G5M0359
8) Remove belt from outlet in rear quarter along

slit.
13
4. Rear Seat Belt
9) Remove inner bolts which secure outer seat. 6) Remove 7/16-20 UNF nuts which secure ELR
10) Remove washer from bolt, then remove bolt, and remove ELR.
belt assembly, and anchor plate bracket. CAUTION:
11) Remove inner bolts (2 places) from center Remove outer seat belt and center seat belt in
seat. similar manner used to remove those from
Sedan.
G5M0360
G5M0362
12) Remove washer from bolt, and remove bolt,
belt assembly and anchor plate bracket. 7) Installation is in the reverse order of removal.
13) Installation is in the reverse order of removal. Ensure that seat belt is properly reeled on and off
Ensure that seat belt is properly reeled on and off after installation of ELR.
after installation of ELR.
CAUTION:
CAUTION: I Be extremely careful not to confuse center
I Be extremely careful not to confuse center seat anchor plate with outer seat anchor plate
seat anchor plate with outer seat anchor plate during installation.
during installation. I Ensure that seat belts are free from twisting
I Ensure that seat belts are free from twisting after installation.
after installation. I Ensure that tongues, buckles and belts are
I Ensure that tongues, buckles and belts are properly placed on seat.
properly placed on seat.
2. WAGON MODEL
1) Raise rear cushion.
2) Remove rear backrest from body.
3) Remove shoulder anchor cover and anchor
bolt.
4) Remove lower portion of rear quarter trim.
5) Remove lap anchor cover and bolt.
G5M0361
14
5. Inner Trim Panel
5. Inner Trim Panel 3. REAR QUARTER PILLAR UPPER TRIM

PANEL (WAGON)
A: REMOVAL AND INSTALLATION 1) Set rear seat cushion up.
1. FRONT PILLAR UPPER TRIM PANEL 2) Remove rear seat backrest.
3) Remove rear quarter lower trim.
1) Remove center pillar lower trim panel.
4) Remove rear rail trim.
2) Remove seat belt anchor bolts. 5) Remove rear quarter upper front trim.
3) Pry pawls off body flange of front pillar upper 6) Remove rear quarter upper rear trim.
trim panel using screwdriver.
4) Remove clips which hold front pillar upper trim
panel, and lift trim panel out by moving it toward
the compartment.
G5M0365

CAUTION:
G5M0363 Be sure to securely hook pawls of rear quarter
pillar trim panel on body flange.
4. REAR QUARTER LOWER TRIM PANEL
CAUTION:
(WAGON)
Be sure to securely hook pawls of front pillar
upper trim panel on body flange. 1) Remove luggage cover.
2) Set rear seat cushion up.
2. REAR PILLAR UPPER TRIM PANEL 3) Remove rear seat backrest.
(SEDAN) 4) Remove rear skirt trim.
1) Remove rear seat cushion and backrest. 5) Remove clip and screw then disconnect con-
2) Remove tapping screw from rear pillar lower nector (RH side).
trim panel, and remove trim panel by sliding it for- 6) Remove rear seat belt lower anchor then
ward. remove rear quarter lower trim.
3) Remove front pillar upper trim end.
4) Pry the pawl off front end using screwdriver.
5) Remove clips which hold rear pillar upper trim,
and remove trim panel by sliding it forward.
H5M0707

CAUTION:
Be careful not to ride trim panel over harness,
G5M0364
insulators, etc.
CAUTION:
Be sure to securely hook pawls of rear pillar
upper trim panel on body flange.
15
5. Inner Trim Panel
5. FLOOR MAT 9) Remove four clips under front seat.

Supplemental Restraint System “Airbag” Air- 10) Remove four clips in toe board area.
bag system wiring harness is routed near floor NOTE:
mat. When pulling out edge, do not pull mat alone; pull
CAUTION: mat together with edge. Pry off two steel clips on
I All Airbag system wiring harness and con- side sill front cover and one on side sill rear cover
nectors are colored yellow. Do not use electri- using screwdriver.
cal test equipment on these circuit. 11) Remove mat hook.
I Be careful not to damage Airbag system wir- 12) Remove mat from toe board area.
ing harness when servicing floor mat.
1) Remove front seats.
2) Remove rear seat cushion.
3) Remove center tray, indicator cover, cover
assembly, and console box, depending on the
specifications.
4) Remove front pillar lower trim panel.
5) Remove center pillar lower trim panel.
6) Remove three clips under rear seat cushion.
7) Remove rear cover side plate and rear pillar
lower trim. G5M0368
8) Pull out edge in the groove of side sill cover.
13) Remove mat from heater unit.
14) Roll mat, and take it out of opened rear door.
NOTE:
I Secure mat firmly with hook and velcro tape.
I Insert mat edge firmly into the groove of side sill
cover.
G5M0367
16
1. Instrument Panel
1. Instrument Panel
H5M0931A
(1) Pad & frame (12) Pocket (23) Ash tray

(2) Grille side (D) (13) Panel center (24) Console box
(3) Front def. grille (14) Center pocket lid (25) Console pocket
(4) Grille side (P) (15) Grille center (26) Rear console BRKT
(5) Grille vent (P) (16) Cup holder (27) Front cover
(6) Glove box panel (17) Side pocket
(7) Glove box lid (18) Lower cover ASSY Tightening torque: N·m (kg-m, ft-lb)
(8) Knob (19) Meter visor T: 7±1 (0.7±0.1, 5.1±0.7)
(9) Instrument panel center console (20) Grille vent (D)
(10) BRKT (Radio) (21) Console cover
(11) Center console cover (22) Console lid
2
1. Instrument Panel
1. Instrument Panel 6) Disconnect data link connector (A) from lower

cover.
A: REMOVAL
Airbag system wiring harness is routed on steering
support beam.
CAUTION:
I All Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
I Be careful not to damage Airbag system wir-
ing harness when servicing the instrument
panel. S5M0045A
1) Disconnect GND cable from battery.

7) Remove knee panel.
2) Remove shift knob (MT model).
3) Remove console cover (A) and front cover (B).
S5M0046
S5M0042A 8) Remove glove box.

4) Remove console box.
S5M0047A
S5M0043 9) Remove center panel and disconnect connec-

tor.
5) Remove lower cover and then disconnect con-
10) Remove audio.
nector.
S5M0048A
S5M0044A
3
1. Instrument Panel
11) Remove two bolts and lower steering column. 13) Disconnect temperature control cable and
mode control cable from heater unit then discon-
nect recirc control cable from intake unit.
NOTE:
Do not move switch and link when installing.
G5M0278
12) Set temperature control switch to “FULL

HOT”, mode selector switch to “DEF” position and
recirc switch to “FRESH” position.
S5M0049A
4
1. Instrument Panel
14) Disconnect harness connectors and then remove the installing bolts and nuts.
CAUTION:
Be sure to hold socket section and not harness when disconnecting.
NOTE:
Put matching mark, if necessary, for easy reassembly.
S5M0050A
5
1. Instrument Panel
15) Remove front defroster grille and two bolts. B: INSTALLATION

Installation is in the reverse order of removal.
CAUTION:
I Be careful not to snag the harness.
I Make sure to connect harness connectors.
I Take care not to scratch the instrument panel
and related parts.
NOTE:
When setting instrument panel into position, push
two pins into grommet on body panel.
S5M0051
16) Remove instrument panel carefully from the

body.
CAUTION:
I Take care not to scratch the instrument panel
and related parts.
I When storing removed instrument panel with
passenger airbag module, place it standing up
on the floor.
S5M0052A
G5M0602
6
1. SRS Airbag
1. SRS Airbag
H5M0963A
(1) Combination switch ASSY with (6) Airbag control module Tightening torque: N·m (kgf-m, ft-lb)
roll connector (7) Airbag main harness
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
(2) TORXTbolt T30 (8) Front sub sensor harness (RH)
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Airbag module ASSY (Driver) (9) Front sub sensor harness (LH)
T3: 10±2 (1.0±0.2, 7.2±1.4)
(4) Airbag module ASSY (Passen- (10) Front sub sensor (RH)
ger) (11) Front sub sensor (LH) T4: 20±4 (2.0±0.4, 14.5±2.9)
(5) TORXT bolt T40 T5: 25±2 (2.5±0.2, 18.1±1.4)
2
1. General
1. General I When checking the system, be sure to use a

digital circuit tester. Use of an analog circuit tester
A: PRECAUTION may cause the airbag to activate erroneously. Do
I If any of the airbag system parts such as not directly apply the tester probe to any connec-
sensors, airbag module, airbag control module and tor terminal of the airbag. When checking, use a
harness are damaged or deformed, replace with test harness.
new genuine parts.
G5M0293
G5M0291
I When servicing, be sure to turn the ignition

switch off, disconnect the negative (−) battery ter-
minal then the positive (+) terminal in advance, and
wait for more than 20 seconds before starting
work.
G5M0292
G5M0294
3
1. General
I Do not drop the airbag modulator parts, subject I Install the wire harness securely with the speci-
it to high temperatures over 90°C (194°F), or apply fied clips so as to avoid interference or jamming
oil, grease, or water to it; otherwise, the internal with other parts.
parts may be damaged and its reliability greatly
lowered.
G5M0297
I Before connecting the airbag system to ground,

make sure that the grounding terminal is free from
paint and contamination.
I Do not allow water or oil to come in contact with
the connector terminals. Do not touch the connec-
tor terminals.
G5M0295
I If any damage or open is found on the SRS air-

bag system wire harness, do not attempt to repair
using soldering, etc. Be sure to replace the faulty G5M0298
harness with a new genuine part.
I When cpnnecting or disconnecting airbag
connector, make sure ignition switch is OFF.
G5M0296
4
SERVICE PROCEDURE [W2F2] 5-5
2. Inspection and Replacement Standards
2. Inspection and Replacement D: AIRBAG CONTROL MODULE

Standards 1. INSPECTION STANDARD
A: VEHICLES WHICH BECOME I A vehicle damaged in a collision (regardless of
whether or not airbag is deployed).
INVOLVED IN A COLLISION I The designated trouble code is output during
If the vehicle equipped with an SRS airbag sys- self-diagnosis. (Refer to “Diagnostics” Section.)
tem is damaged in a collision, the airbag sys-
tem parts must be checked and replaced in 2. REPLACEMENT STANDARD
accordance with the following standards: I Control module is cracked or deformed.
I After faulty parts are replaced, the warning I Mounting bracket is cracked or deformed.
light operation must be checked. I Connector is scratched or cracked.
I When the ignition switch is turned ON, it I Control module dropped to the floor/ground.
lights up for 8 seconds and then it goes out for I Control module determined as faulty during
at least 30 seconds. diagnostics.
I The trouble code stored in memory must be I Airbag is deployed.
erased after the check.
E: COMBINATION SWITCH
B: AIRBAG MODULE (DRIVER AND
1. INSPECTION STANDARD
PASSENGER)
I A vehicle damaged in a collision (regardless of
1. INSPECTION STANDARD whether or not airbag is deployed).
I The vehicle damaged in a collision (regardless I The designated trouble code is output during
of whether or not airbag is deployed). self-diagnosis. (Refer to “Diagnostics” Section.)
I The designated trouble code is output during
self-diagnosis. (Refer to “Diagnostics” Section.) 2. REPLACEMENT STANDARD
I Combination switch or steering roll connector is
2. REPLACEMENT STANDARD deformed or cracked.
I Airbag is deployed.
I The pad surface is scratched or cracked. F: STEERING WHEEL
I Harness and/or connector is deformed or 1. INSPECTION STANDARD
cracked, their circuits are broken, lead wire is
exposed, etc. I A vehicle damaged in a collision (regardless of
I Mounting bracket is cracked or deformed. whether or not airbag is deployed).
I The module surface is fouled with foreign mat-
ter. (grease, oil, water, cleaning solvent, etc.)
2. REPLACEMENT STANDARD
I Airbag module dropped to the floor/ground. I Check steering wheel insert for cracks or defor-
I Airbag module determined as faulty during self- mities.
diagnosis. I Check to ensure that new airbag module is prop-
erly installed in steering wheel
C: MAIN HARNESS I After installing airbag module, check to ensure
that it is free of interference with steering wheel
1. INSPECTION STANDARD and that clearance between the two is equal at all
I A vehicle damaged in a collision (regardless of points.
whether or not airbag is deployed).
self-diagnosis. (Refer to “Diagnostics” Section.)
2. REPLACEMENT STANDARD
I Harness circuit is broken, lead wire is exposed,
corrugated tube is cracked, etc.
I Connector is scratched or cracked.
self-diagnosis.
B5M0095
5
5-5 [W2G1] SERVICE PROCEDURE
2. Inspection and Replacement Standards
G: STEERING COLUMN ASSEMBLY 2. REPLACEMENT STANDARD

1. INSPECTION STANDARD I Bracket is deformed.
I Housing is cracked or deformed.
I A vehicle damaged in a collision (regardless of I The label (that identifies the manufacturing num-
whether or not airbag is deployed). ber) is peeled or deteriorated.
I Harness circuit is broken, lead wire is exposed,
2. REPLACEMENT STANDARD corrugated tube is cracked, etc.
I Check to ensure that clearance of expand plate I Front sub sensor determined as faulty as a
on steering column under side is within specifica- result of Diagnostics.
tions. I Airbag is deployed.
I Front sub sensor dropped to the floor/ground.
Clearance of expand plate: L
More than 15 mm (0.59 in)
S5M0213A
H: FRONT SUB SENSOR

1. INSPECTION STANDARD
I Check the front section (Refer to shaded area of
vehicle in figure) for damage, regardless of
whether or not airbag is deployed.
G5M0311

self-diagnosis. <Ref. to 5-5 [T4A0].>
6
3. Airbag Module
3. Airbag Module I Do not check airbag module (driver side and

passenger side) continuity with airbag
A: REMOVAL AND INSTALLATION removed from the vehicle body.
CAUTION:
I The airbag module (driver side and passen-
ger side) must not be disassembled. The airbag
module cannot be used again once inflated.
G5M0302
I Replace airbag module (driver side and pas-

senger side) with a new one, should any of the
following conditions develop:
G5M0299
I Pad surface is scratched or cracked.
I When removing and installing the airbag I Connector harness is damaged.
module (driver side and passenger side), the I Inflator side structure of module is
operator should stand, as much as possible, cracked or deformed.
on the side of the airbag module. I Module is excessively stained with water,
oil, etc.
I Module was accidentally dropped.
I When storing a removed airbag module
(driver side and passenger side), be sure to
place it in parallel with floor with the pad facing
up. Do not place it against a wall, or place any-
thing on the pad; otherwise, a dangerous con-
dition may be created if the module malfunc-
tions.
G5M0300
I After removal, the airbag module (driver side

and passenger side) should be kept away from
heat and light sources, and stored on a clean,
flat surface to prevent from any damage to its
lower structure.
G5M0301
7
3. Airbag Module
G5M0604
8
3. Airbag Module
1. DRIVER SIDE 4) Disconnect airbag connector. <Ref. to 5-5

[M2F2].>
1) Set front wheels in straight ahead position.
2) Turn ignition switch off.
3) Disconnect ground cable from battery and wait
for at least 20 seconds before starting work.
4) Using TORXT BIT T30, remove two TORXT
bolts.
S5M0214
5) Remove seven bolts and then carefully remove

airbag module.
H5M0662A
5) Disconnect airbag connector on back of airbag

module. <Ref. to 5-5 [M2F2].>
S5M0215
6) Refer to “CAUTION:” for handling of a removed

airbag module. <Ref. to 5-5 [W3A0].>
CAUTION:
H5M0664 Do not allow harness and connectors to inter-
fere or get caught with other parts.
6) Refer to “CAUTION:” for handling of a removed
CAUTION:
Do not allow harness and connectors to inter-
fere or get caught with other parts.
2. PASSENGER SIDE
3) Remove glove box. <Ref. to 5-4 [W1A0].>
9
4. Main Harness
4. Main Harness 8) Disconnect front sub sensor connector from air-

bag main harness.
A: REMOVAL AND INSTALLATION 9) Detach clips from steering support beam and
remove main harness.
3) Remove lower cover. <Ref. to 5-4 [W1A0].>
4) Disconnect airbag connector (AB3) and (AB8)
below steering column. <Ref. to 5-5 [M2F2].>
CAUTION:
Do not reconnect airbag connector at steering
column until main harness are securely re-in-
stalled.
H5M0933A
G5M0312
5) Remove instrument panel. <Ref. to 5-4

[W1A0].>
6) Disconnect connector from airbag control mod-
ule.
S5M0216
7) Disconnect body harness connector (B31) from

connector (AB1).
S5M0217A
10
5. Airbag Control Module
5. Airbag Control Module 3) Remove lower cover. <Ref. to 5-4 [W1A0].>

4) Disconnect airbag connector (AB3) and (AB8)
A: REMOVAL AND INSTALLATION below steering column.
CAUTION: CAUTION:
I Do not disassemble the airbag control mod- Do not reconnect airbag connector at steering
ule. column until airbag control module is securely
re-installed.
G5M0322
G5M0312
I If the airbag control module is deformed, or
5) Remove instrument panel console. <Ref. to 5-4
if water damage is suspected, replace the air-
[W1A0].>
bag control module with a new genuine part. 6) Disconnect connector from airbag control mod-
ule.
7) Using T40 TORXT bit (Tamper resistant type),
remove four TORXT bolts in numerical sequence
shown in figure. Discard the old TORXT bolts.
CAUTION:
Use new TORXT bolts during re-assembly.
G5M0323
I After removal, keep the airbag control mod-

ule on a dry, clean surface away from heat and
light sources, and moisture and dust.
S5M0219A
G5M0324

11
6. Combination Switch
6. Combination Switch 7) Using steering puller, remove steering wheel.

CAUTION:
A: REMOVAL Do not allow connector to interfere when
1) Turn ignition switch off. removing steering wheel.
Disconnect airbag connector (AB3) and (AB8)
below steering column.
CAUTION:
column until combination switch is securely re-
installed.
G5M0332
8) Remove steering column covers.

9) Removing three retaining screws, remove com-
bination switch.
G5M0312
4) Disconnect combination switch connectors

from body harness connector.
Using T30 TORXT bit, remove two TORXT bolts.
S5M0220
B: ADJUSTMENT
1. CENTERING ROLL CONNECTOR
Before installing steering wheel, make sure to cen-
ter roll connector built into combination switch.
1) Make sure that front wheels are positioned
straight ahead.
2) Install steering gearbox, steering shaft and
H5M0662A combination switch properly. Turn roll connector
pin (A) clockwise until it stops.
6) Disconnect airbag connector on back of airbag
3) Then, back off roll connector pin (A) approxi-
module. Remove airbag module, and place it with
mately 2.5 turns until “G” marks aligned.
pad side facing upward. <Ref. to 5-5 [W3A0].>
H5M0663B
H5M0664
12
7. Front Sub Sensor
C: INSTALLATION 7. Front Sub Sensor

CAUTION: A: REMOVAL AND INSTALLATION
Failure to do this might damage roll connector.
CAUTION:
1) Before installing combination switch, check to
I If the front end of the vehicle body is dam-
ensure that combination switch is off and front
wheels are set in the straight ahead position. aged by a collision, be sure to check the left
2) Install column cover and center roll connector. and right front sub sensors, even if the airbag
<Ref. to 5-5 [W6B1].> was not inflated. If any damage to the sensor or
3) Install steering wheel in neutral position. Care- any deformation of the sensor mount is found,
fully insert roll connector pin (A) into hole on steer- replace with a new genuine part.
ing wheel.
NOTE:
If steering wheel angle requires fine adjustment,
adjust tie-rod. <Ref. to 4-3 [W3F0].>
G5M0291
I When painting or performing sheet metal

work on the front part of vehicle body, includ-
ing the front wheel apron, front fender and
H5M0663B front side frame, take utmost care not to apply
4) Install airbag module and lower cover in the dryer heat, painting mist, or the flame of the
reverse order of removal. welding burner directly to the front sub sen-
sors and wire harness of the airbag system.
G5M0310
1. FRONT SUB SENSOR HARNESS

13
7. Front Sub Sensor
4) Disconnect airbag connector (AB3) and (AB8) 8) Remove wiring harness clips.
below steering column.
CAUTION:
column until front sub sensors are securely re-
installed.
G5M0315
9) Remove grommet and then detach front sub

sensor harness.
G5M0312
5) Remove front side sill cover and then discon-

nect front sub sensor connector. <Ref. to 5-5
[M2F2].>
G5M0316
2. FRONT SUB SENSOR ASSEMBLY

B5M0517 3) Remove front wheel and mud guard.
4) Disconnect connector from front sub sensor
6) Remove front wheel and mud guard. assembly. <Ref. to 5-5 [M2F3].>
7) Disconnect connector from front sub sensor
assembly. <Ref. to 5-5 [M2F3].>
B5M0518
B5M0518
14
7. Front Sub Sensor
5) Remove front sub sensor.
B5M0519
15
5-5 SERVICE PROCEDURE
MEMO:
16
5-5 [T100] DIAGNOSTICS
1. Electrical Components Location
H5M0934A
Connector No. (AB1) (AB2) (AB3) (AB6) (AB7) (AB8) (AB9)

Pole 7 2 2 28 2 2 2
Color Yellow Yellow Yellow Yellow Yellow Yellow Yellow
Male/Female Male Male Male Female Female Female Female
Connector No. (AB10) (AB11) (AB12) (AB13) (AB14) (AB15) (AB16)

Pole 2 2 2 2 2 2 2
Color Yellow Blue Blue Yellow Blue Blue Yellow
Male/Female Male Female Male Female Female Male Female
2
DIAGNOSTICS [T200] 5-5
2. Schematic
2. Schematic
H5M0942A
3
3. Tools for Diagnostics

CAUTION:
Be sure to use specified test harness A, I or I2, F and H when measuring voltage, resistance, etc.
of AIRBAG system component parts.
A: TEST HARNESS A
B5M0112A
4
DIAGNOSTICS [T3B0] 5-5
B: TEST HARNESS I
S5M0340A
5
5-5 [T3C0] DIAGNOSTICS
C: TEST HARNESS I2
B5M0927A
6
DIAGNOSTICS [T3D0] 5-5
D: TEST HARNESS F
S5M0247A
7
5-5 [T3E0] DIAGNOSTICS
E: TEST HARNESS H
B5M0553B
8
DIAGNOSTICS [T3F0] 5-5
F: AIRBAG RESISTOR
The airbag resistor is used during diagnostics. The airbag resistor has the same resistance as the airbag
module and thus provides safety when used instead of the airbag module. It also makes it possible to finish,
diagnostics in less time.
B5M0114A
9
5-5 [T4A1] DIAGNOSTICS
4. Diagnostics Chart for On-board Diagnostic System
4. Diagnostics Chart for On- 4A4 : CHECK AIRBAG WARNING LIGHT

board Diagnostic System ILLUMINATES.
A: BASIC DIAGNOSTICS Check airbag warning light illuminates.

PROCEDURE : Does airbag warning light come ON
for about 7 seconds, then go out and
4A1 : CHECK AIRBAG WARNING LIGHT stay out?
ILLUMINATES.
: Perform clear memory. <Ref. to 5-5
[T4C0].>
1) Airbag warning light comes ON. : Go to step 4A1.
2) Turn ignition switch to ON (engine OFF).
3) Check airbag warning light illuminates. B: ON-BOARD DIAGNOSTIC
: Does airbag warning light stay ON When the airbag system is in functioning condition,
after about 7 seconds or remain OFF, the airbag warning light will remain on for about 7
or come back ON after 30 seconds? seconds and go out when the ignition switch is set
: Repair and replace. <Ref. to 5-5 to ON.
[T4D0].> If there is any malfunction, the airbag warning light
: Go to step 4A2. will either stay on or off continuously. In such
cases, perform on-board diagnostic in accordance
4A2 : CHECK TROUBLE CODE INDICATES. with the specified procedure to determine trouble
codes.
Perform ON-BOARD DIAGNOSTICS. <Ref. to 5-5 1) Turn ignition switch ON (with engine OFF).
2) Connect DIAG. terminal to No. 1 terminal of
[T4B0].>
diagnosis connector located inside lower cover.
: Does trouble code indicate? <Ref. to
5-5 [T5A0].>
: Repair and replace. <Ref. to 5-5
[T5O0].> Go to step 4A3.
: Repair and replace. <Ref. to 5-5
[T5P0].> Go to step 4A3.
4A3 : CHECK AIRBAG WARNING LIGHT

ILLUMINATES.
B5M0115D
1) Turn ignition switch to ON (engine OFF). 3) Check in accordance with the trouble code indi-
2) Check airbag warning light illuminates. cated by the AIRBAG warning light, and record the
: Does airbag warning light stay ON trouble codes.
after about 7 seconds or come back 4) Turn the ignition switch “OFF” and remove the
ON after 30 seconds? DIAG. terminal from No. 1 terminal of diagnosis
: Repair and replace. <Ref. to 5-5 connector.
[T4D0].>
: Go to step 4A4.
10
C: CLEAR MEMORY D: DIAGNOSTICS PROCEDURE

After eliminating problem as per trouble code, clear
memory as follows: 4D1 : CHECK TROUBLE CODE INDICATES.
1) Make sure ignition switch is ON (and engine

off). Connect one DIAG. terminal “A” on diagnosis 1) Perform on-board diagnostic. <Ref. to 5-5
connector terminal No. 1. [T4B0].>
While warning light is flashing, connect the other 2) Check trouble code indicates.
DIAG. terminal “B” on terminal No. 2 for at least : Are trouble codes 11, 12, 15 or 16
three seconds. indicated? <Ref. to 5-5 [T5A2].>
: Go to step 4D2.
: Perform diagnostics and repair accord-
ing to indicated trouble code. <Ref. to
5-5 [T5A0].>
4D2 : CHECK TROUBLE CODE INDICATES.
Check trouble code indicates.

: Are trouble codes 12, 16 indicated?
B5M0116D
<Ref. to 5-5 [T5A2].>
2) After memory is cleared, normal warning light : Go to step 4D3.
flashing rate resumes. (Warning light flashes every : Go to step 4D4.
0.6 seconds ON-OFF operation.) Memory cannot
be cleared if any problem exists.
3) After clear memory and then DIAG. terminals 4D3 : CHECK AIRBAG WARNING LIGHT
“A” and “B”, extract from diagnosis connector. ILLUMINATES.
1) Turn ignition switch to OFF. Disconnect battery

ground cable, and wait 20 seconds.
2) Remove glove box <Ref. to 5-4 [W1A0].> and
disconnect passenger’s airbag module connector
(AB9) to (AB10). <Ref. to 5-5 [W3A2].>
3) Connect test harness F connector (1F) to
(AB9).
4) Connect airbag resistor to test harness F con-
nector (3F).
S5M0249A
11
5-5 [T4D4] DIAGNOSTICS
5) Remove lower cover panel <Ref. to 5-4 4D4 : CHECK AIRBAG WARNING LIGHT
[W1A0].> and connect test harness F connector ILLUMINATES.
(1F) to (AB8) with airbag resistor attached to test
harness F connector (3F).
1) Turn ignition switch to “OFF”. Disconnect bat-
tery ground cable, and wait 20 seconds.
2) Connect connector (AB8) to (AB3).
3) Remove driver’s airbag module and connect
test harness F connector (1F) to (AB7). <Ref. to
5-5 [W3A1].>
4) Connect airbag resistor to test harness F con-
nector (3F).
S5M0250A
6) Connect battery ground cable and turn ignition

switch to ON.
7) Check airbag warning light illuminates.
NOTE:
In some cases the airbag warning light will go OFF
after about 7 seconds but will turn ON again within
S5M0251A
30 seconds. In this case continue diagnostics with
the basic diagnostics procedures or trouble code 5) Connect battery ground cable and turn ignition
procedures. switch to ON.
: Does airbag warning light go off after 6) Check airbag warning light illuminates.
about 7 seconds and remain off for NOTE:
more than 30 seconds? In some cases the airbag warning light will go OFF
: Replace with a new passenger’s airbag after about 7 seconds but will turn ON again within
module. <Ref. to 5-5 [W3A2].> Go to 30 seconds. In this case continue diagnostics with
step 4D6. the basic diagnostics procedures or trouble code
: Perform diagnostics and repair accord- procedures.
ing to indicated trouble code. <Ref. to : Does airbag warning light go off after
5-5 [T5A0].> about 7 seconds and remain off for
more than 30 seconds?
: Replace with a new driver’s airbag mod-
ule. <Ref. to 5-5 [W3A1].> Go to step
4D6.
: Go to step 4D5.
12
4D5 : CHECK AIRBAG WARNING LIGHT 4D6 : CHECK AIRBAG WARNING LIGHT
ILLUMINATES. ILLUMINATES.
1) Turn ignition switch to OFF. Disconnect battery 1) Connect battery ground cable and turn ignition
ground cable, and wait 20 seconds. switch to ON.
2) Remove lower cover panel and connect test 2) Check airbag warning light illuminates.
harness F connector (1F) to (AB8) <Ref. to 5-4 NOTE:
[W1A0].> with airbag resistor attached to test har- In some cases the airbag warning light will go OFF
ness F connector (3F). after about 7 seconds but will turn ON again within
the basic diagnostics procedures or trouble code
procedures.
: Does airbag warning light go off after
about 7 seconds and remain off for
[T4C0].>
: Go to step 4D1.
S5M0250A

switch to ON.
4) Check airbag warning light illuminates.
NOTE:
In some cases the airbag warning light will go OFF
after about 7 seconds but will turn ON again within
the basic diagnostics procedures or trouble code
procedures.
: Does airbag warning light go off after
about 7 seconds and remain off for
: Replace with a new combination switch.
<Ref. to 5-5 [W600].> Go to step 4D6.
: Perform diagnostics and repair accord-
ing to indicated trouble code. <Ref. to
5-5 [T5A0].>
13
5. Diagnostics Chart with Trouble Code

A: TROUBLE CODES
1. LIST OF TROUBLE CODES
Trouble code/ Memory
Contents of diagnosis Index No.
Contents of troubles function
I Airbag main harness circuit is open, shorted or shorted
to ground.
I Airbag module harness (driver) circuit is open, shorted
11 Provided. or shorted to ground. <Ref. to 5-5 [T5B0].>
I Roll connector circuit is open, shorted or shorted to
ground.
I Airbag control module is faulty.
I Airbag main harness circuit is open, shorted or shorted
to ground.
12 Provided. I Airbag module harness (passenger) circuit is open, <Ref. to 5-5 [T5C0].>
shorted or shorted to ground.
I Airbag main harness circuit (driver) is shorted to power
supply.
I Airbag module harness (driver) is shorted to power sup-
15 Provided. <Ref. to 5-5 [T5D0].>
ply.
I Roll connector is shorted to power supply.
I Airbag main harness circuit (passenger) is shorted to
power supply.
16 Provided. I Airbag module harness (passenger) is shorted to power <Ref. to 5-5 [T5E0].>
supply.
21 Provided. Airbag control module is faulty. <Ref. to 5-5 [T5F0].>
22 Provided. Front airbag module is inflated. <Ref. to 5-5 [T5G0].>
23 Not provided. (AB6) is not connected properly to airbag control module. <Ref. to 5-5 [T5H0].>
I Airbag main harness circuit is open.
24 Not provided. <Ref. to 5-5 [T5I0].>
I Fuse No. 11 (in joint box) is blown.
I Body harness circuit is open.
I Airbag main harness circuit is open.
25 Provided. <Ref. to 5-5 [T5J0].>
I Front sub sensor harness (RH) circuit is shorted.
I Front sub sensor harness (RH) circuit is open.
31 Provided. <Ref. to 5-5 [T5K0].>
I Front sub sensor (RH) is faulty.
I Front sub sensor harness (LH) circuit is shorted.
I Front sub sensor harness (LH) circuit is open.
32 Provided. <Ref. to 5-5 [T5L0].>
I Front sub sensor (LH) is faulty.
I Airbag warning light is faulty.
I Airbag control module to airbag warning light harness
circuit is shorted or open.
Airbag warning light I Grounding circuit is faulty.
Not provided. <Ref. to 5-5 [T5M0].>
remains on. I Airbag control module is faulty.
I (AB1) and (B31) are not connected properly.
I (AB6) is not connected properly to airbag control mod-
ule.
14
DIAGNOSTICS [T5A2] 5-5
Trouble code/ Memory

Contents of diagnosis Index No.
Contents of troubles function
Airbag warning light
Not provided. I Airbag warning light is faulty. <Ref. to 5-5 [T5N0].>
remains off.
I Airbag main harness is faulty.
Warning light indicates
trouble code, then nor-
Provided. Airbag system component parts are faulty. <Ref. to 5-5 [T5O0].>
mal code. (Flashing
trouble code.)
I Airbag connector is faulty.
Warning light indicates
trouble code, then nor-
Not provided. I Airbag main harness is faulty. <Ref. to 5-5 [T5P0].>
mal code. (Flashing nor-
mal code.)
I Body harness is faulty.
2. HOW TO READ TROUBLE CODES

The AIRBAG warning light flashes a code corresponding to the faulty parts.
The long segment (1.2 sec on) indicates a “ten”, and the short segment (0.3 sec on) indicates a “one”.
B5M0117A
15
5-5 [T5B0] DIAGNOSTICS
B: TROUBLE CODE 11 5B1 : AIRBAG MAIN HARNESS INSPEC-

DIAGNOSIS: TION
I Airbag main harness circuit is open, shorted or
shorted to ground. 1) Remove lower cover panel <Ref. to 5-4
I Airbag module harness (Driver) circuit is open, [W1A0].>, and connect connector (AB8) below
shorted or shorted to ground. steering column to test harness F connector (1F).
I Roll connector circuit is open, shorted or shorted
to ground.
CAUTION:
Before performing diagnostics on airbag
system, turn ignition switch “OFF”, disconnect
battery ground cable and then wait at least 20
seconds.
After 20 seconds elapse, remove instrument
panel lower cover, and disconnect (AB3) and
S5M0258A
(AB8), (AB9) and (AB10).
2) Disconnect connector (AB6) <Ref. to 5-5
[W5A0].> from airbag control module, and connect
it to test harness I or I2 connector (1I) terminal.
3) Measure resistance between test harness I or
I2 connector (2I) and test harness F connector (3F)
terminals.
Connector & terminal
(2I) No. 1 — (3F) No. 3:
S5M0259B
: Is resistance less than 10 Ω?

: Go to step 5B2.
: Replace airbag main harness. <Ref. to
5-5 [W4A0].>
16
5B2 : AIRBAG MAIN HARNESS INSPEC- 5B4 : AIRBAG MAIN HARNESS INSPEC-
TION TION
Measure resistance between test harness I or I2 1) Disconnect connector (AB6) from airbag control
connector (2I) and test harness F connector (3F) module <Ref. to 5-5 [W5A0].>, and connect it to
terminals. test harness I or I2 connector (1I).
Connector & terminal I2 connector (2I) terminals and chassis ground.
(2I) No. 4 — (3F) No. 4:
(2I) No. 4 (+) — Chassis ground (−):
S5M0260B
: Is resistance less than 10 Ω? S5M0276B
: Go to step 5B3. : Is resistance more than 200 Ω?

: Replace airbag main harness. <Ref. to : Go to step 5B5.
5-5 [W4A0].> : Replace airbag main harness. <Ref. to
5-5 [W4A0].>
5B3 : AIRBAG MAIN HARNESS INSPEC-
TION 5B5 : AIRBAG MAIN HARNESS INSPEC-
TION
1) Disconnect connector (AB6) from airbag control
module <Ref. to 5-5 [W5A0].>, and connect it to Measure resistance between test harness I or I2
test harness I or I2 connector (1I). connector (2I) terminals and chassis ground.
I2 connector (2I) terminal. Connector & terminal
(2I) No. 1 — No. 4:
S5M0277B
S5M0261B : Is resistance more than 200 Ω?

: Replace airbag control module. <Ref. to
: Is resistance more than 10 kΩ? 5-5 [W5A0].>
: Go to step 5B4. : Replace airbag main harness. <Ref. to
: Replace airbag main harness. <Ref. to 5-5 [W4A0].>
5-5 [W4A0].>
17
C: TROUBLE CODE 12 5C2 : AIRBAG MAIN HARNESS INSPEC-

DIAGNOSIS: TION
I Airbag main harness circuit is open, shorted or
shorted to ground. Measure resistance between test harness I or I2
I Airbag module harness (Passenger) circuit is connector (2I) and test harness F connector (3F)
open, shorted or shorted to ground. terminals.
CAUTION: (2I) No. 5 — (3F) No. 4:
seconds.
(AB8), (AB9) and (AB10).
5C1 : AIRBAG MAIN HARNESS INSPEC-

TION
S5M0263B
1) Remove glove box. <Ref. to 5-4 [W1A0].>

2) Disconnect connector (AB9) and (AB10) <Ref. : Is resistance less than 10 Ω?
to 5-5 [W3A2].> and connect connector (AB9) to : Go to step 5C3.
test harness F connector (1F). : Replace airbag main harness. <Ref. to
3) Disconnect connector (AB6) <Ref. to 5-5 5-5 [W4A0].>
[W5A0].> from airbag control module, and connect
it to test harness I or I2 connector (1I) terminal.
4) Measure resistance between test harness I or 5C3 : AIRBAG MAIN HARNESS INSPEC-
I2 connector (2I) and test harness F connector (3F) TION
terminals.
Connector & terminal 1) Disconnect connector (AB6) from airbag control
(2I) No. 2 — (3F) No. 3: module <Ref. to 5-5 [W5A0].>, and connect it to
test harness I or I2 connector (1I).
I2 connector (2I) terminal.
(2I) No. 2 — No. 5:
S5M0262B

: Go to step 5C2.
S5M0252B
5-5 [W4A0].>
: Is resistance more than 10 kΩ?
: Go to step 5C4.
5-5 [W4A0].>
18
5C4 : AIRBAG MAIN HARNESS INSPEC- D: TROUBLE CODE 15

TION DIAGNOSIS:
I Airbag main harness circuit (Driver) is shorted to
1) Disconnect connector (AB6) from airbag control power supply.
module <Ref. to 5-5 [W5A0].>, and connect it to I Airbag module harness (Driver) is shorted to
test harness I or I2 connector (1I). power supply.
2) Measure resistance between test harness I or I Roll connector is shorted to power supply.
I2 connector (2I) terminals and chassis ground. I Airbag control module is faulty.
Connector & terminal CAUTION:
(2I) No. 2 (+) — Chassis ground (−): Before performing diagnostics on airbag
battery ground terminal and then wait at least
20 seconds.
(AB8), (AB9) and (AB10).
5D1 : AIRBAG MAIN HARNESS INSPEC-

TION
S5M0278B
: Is resistance more than 200 Ω? module <Ref. to 5-5 [W5A0].>, and connect it to
: Go to step 5C5. 2) Connect battery ground cable and turn ignition
: Replace airbag main harness. <Ref. to switch “ON” (engine off).
5-5 [W4A0].> 3) Measure voltage across each test harness I or
I2 connector (2I) terminal and chassis ground.
5C5 : AIRBAG MAIN HARNESS INSPEC- Connector & terminal
TION (2I) No. 4 (+) — Chassis ground (−):
Measure resistance between test harness I or I2

connector (2I) terminals and chassis ground.
S5M0280B
: Is voltage less than 1 V?

: Go to step 5D2.
S5M0279B
5-5 [W4A0].>
: Is resistance more than 200 Ω?
5-5 [W5A0].>
5-5 [W4A0].>
19
5D2 : AIRBAG MAIN HARNESS INSPEC- E: TROUBLE CODE 16

TION DIAGNOSIS:
I Airbag main harness circuit (Passenger) is
Measure voltage across each test harness I or I2 shorted to power supply.
connector (2I) terminal and chassis ground. I Airbag module harness (Passenger) is shorted
Connector & terminal to power supply.
(2I) No. 1 (+) — Chassis ground (−): I Airbag control module is faulty.
CAUTION:
battery ground terminal and then wait at least
20 seconds.
(AB8), (AB9) and (AB10).
5E1 : AIRBAG MAIN HARNESS INSPEC-

S5M0281B TION

: Replace airbag control module. <Ref. to module <Ref. to 5-5 [W5A0].>, and connect it to
5-5 [W5A0].> test harness I or I2 connector (1I).
: Replace airbag main harness. <Ref. to 2) Connect battery ground cable and turn ignition
5-5 [W4A0].> switch “ON” (engine off).
3) Measure voltage across each test harness I or
I2 connector (2I) terminal and chassis ground.
S5M0274B

: Go to step 5E2.
5-5 [W4A0].>
20
5E2 : AIRBAG MAIN HARNESS INSPEC- F: TROUBLE CODE 21

TION DIAGNOSIS:
Airbag control module is faulty.
Measure voltage across each test harness I or I2 CAUTION:
connector (2I) terminal and chassis ground. Before performing diagnostics on airbag
Connector & terminal system, turn ignition switch “OFF”, disconnect
(2I) No. 5 (+) — Chassis ground (−): battery ground terminal, and then wait at least
20 seconds.
5F1 : CHECK IF TROUBLE CODE 21 IS

INDICATED.
Confirm flashing trouble code according to “BASIC

DIAGNOSTICS PROCEDURE”. <Ref. to 5-5
[T4A0].>
: Is airbag warning light trouble code
21 indicated?
S5M0275B
5-5 [W5A0].>
[T4C0].>
5-5 [W5A0].>
5-5 [W4A0].>
21
5-5 [T5G0] DIAGNOSTICS
G: TROUBLE CODE 22 H: TROUBLE CODE 23

DIAGNOSIS: DIAGNOSIS:
Front airbag module is inflated. (AB6) is not connected properly to airbag control
CAUTION: module.
Before performing diagnostics on airbag CAUTION:
system, turn ignition switch “OFF”, disconnect Before performing diagnostics on airbag
battery ground terminal, and then wait at least system, turn ignition switch “OFF”, disconnect
20 seconds. battery ground cable and then wait at least 20
seconds.
5G1 : CHECK IF TROUBLE CODE 22 IS
INDICATED. 5H1 : CHECK POOR CONTACT IN CON-
NECTOR (AB6).
Confirm flashing trouble code according to “BASIC
DIAGNOSTICS PROCEDURE”. <Ref. to 5-5 Check connector (AB6) connected to airbag con-
[T4A0].> trol module. <Ref. to 5-5 [W5A0].>
: Is airbag warning light trouble code : Is there poor contact in connector
22 indicated? (AB6)?
: Replace airbag control module <Ref. to : Repair poor contact in connector (AB6).
5-5 [W5A0].>, front sub sensor <Ref. to : Replace airbag control module. <Ref. to
5-5 [W7A0].>, driver’s airbag module 5-5 [W5A0].>
<Ref. to 5-5 [W3A1].> and passenger’s
[T4C0].>
22
DIAGNOSTICS [T5I2] 5-5
I: TROUBLE CODE 24 5I2 : AIRBAG MAIN HARNESS INSPEC-

DIAGNOSIS: TION
I Airbag main harness circuit is open. 1) Go to following procedure after performing
I Fuse No. 11 (in joint box) is blown. diagnostics on airbag system as per diagnosis pro-
I Body harness circuit is open. cedure under “5I1 AIRBAG CONTROL MODULE
CAUTION: INSPECTION” <Ref. to 5-5 [T5I1].> previously out-
Before performing diagnostics on airbag lined.
system, turn ignition switch “OFF”, disconnect 2) Turn ignition switch “OFF”, disconnect battery
battery ground cable and then wait at least 20 ground cable and then wait at least 20 seconds.
seconds. 3) Disconnect connector (AB1) from body harness
After 20 seconds elapse, remove instrument connector (B31) at front lower pillar (driver side),
panel lower cover, and disconnect (AB3) and and connect connector (AB1) to test harness A
(AB8), (AB9) and (AB10). connector (2A).
4) Measure resistance between test harness A
5I1 : AIRBAG CONTROL MODULE INSPEC- connector (5A) and test harness I or I2 connector
TION (2I) terminals.
1) Disconnect connector (AB6) from airbag control (5A) No. 9 — (2I) No. 3:
module <Ref. to 5-5 [W5A0].>, and connect it to
switch “ON” (engine off).
3) Measure voltage across connector (2I) terminal
and chassis ground.
S5M0265B

: Go to step 5I3.
5-5 [W4A0].>
S5M0264B
: Is voltage more than 10 V?

5-5 [W5A0].>
: Go to step 5I2.
23
5-5 [T5I3] DIAGNOSTICS
5I3 : AIRBAG MAIN HARNESS INSPEC- 5I5 : FUSE NO. 11 (IN JOINT BOX) INSPEC-
TION TION
Measure resistance between each terminal of con- Make sure ignition switch is turned “OFF”, then
nectors (5A) and chassis ground. remove and visually check fuse No. 11 (in joint
box).
(5A) No. 9 (+) — Chassis ground (−):
S5M0257B
S5M0266A
: Is fuse No. 11 blown?
: Replace fuse No. 11. If fuse No. 11
blows again, repair body harness.
: Go to step 5I4. : Repair body harness.
5-5 [W4A0].>
5I4 : AIRBAG MAIN HARNESS INSPEC-

TION
Measure resistance between each terminal of con-

nectors (2I) and chassis ground.
S5M0267B

: Go to step 5I5.
5-5 [W4A0].>
24
DIAGNOSTICS [T5J2] 5-5
J: TROUBLE CODE 25 5J2 : AIRBAG MAIN HARNESS INSPEC-

DIAGNOSIS: TION
I Airbag main harness circuit is open. 1) Go to following procedure after performing
I Fuse No. 6 (in joint box) is blown. diagnostics on airbag system as per diagnosis pro-
I Body harness circuit is open. cedure under “5J1 AIRBAG CONTROL MODULE
CAUTION: INSPECTION” <Ref. to 5-5 [T5J1].> previously
Before performing diagnostics on airbag outlined.
system, turn ignition switch “OFF”, disconnect 2) Turn ignition switch “OFF”, disconnect battery
battery ground cable and then wait at least 20 ground terminal and then wait at least 20 seconds.
seconds. 3) Disconnect body harness connector (B31) from
After 20 seconds elapse, remove instrument connector (AB1) at front lower pillar, and connect
panel lower cover, and disconnect (AB3) and connector (AB1) to test harness A connector (2A).
(AB8), (AB9) and (AB10).
5J1 : AIRBAG CONTROL MODULE

INSPECTION

module <Ref. to 5-5 [W5A0].> and connect it to test
harness I or I2 connector (1I).
switch “ON”. (engine off) B5M0119B
3) Measure voltage across connector (2I) terminal
and chassis ground. 4) Measure resistance between test harness A
Connector & terminal connector (5A) terminal and test harness I or I2
(2I) No. 6 (+) — Chassis ground (−): connector (2I) terminal.
(5A) No. 1 — (2I) No. 6:
S5M0253B
: Is voltage more than 10 V? S5M0254B

5-5 [W5A0].> : Is resistance less than 10 Ω?
: Go to step 5J2. : Go to step 5J3.
5-5 [W4A0].>
25
5-5 [T5J3] DIAGNOSTICS
5J3 : AIRBAG MAIN HARNESS INSPEC- 5J5 : FUSE NO. 6 (IN JOINT BOX) INSPEC-
TION TION
Measure resistance between (5A) connector termi- 1) Turn ignition switch “OFF”.
nal and chassis ground. 2) Remove and visually check fuse No. 6 (in joint
box).
(5A) No. 1 (+) — Chassis ground (−):
S5M0257A
S5M0255A
: Replace fuse No. 6 if fuse No. 6 blows
again, repair body harness.
: Go to step 5J4. : Repair body harness.
5-5 [W4A0].>
5J4 : AIRBAG MAIN HARNESS INSPEC-

TION
Measure resistance between (2I) connector termi-

nal and chassis ground.
S5M0256B

: Go to step 5J5.
5-5 [W4A0].>
26
DIAGNOSTICS [T5K3] 5-5
K: TROUBLE CODE 31 5K2 : FRONT SUB SENSOR (RH) AND

DIAGNOSIS: FRONT SUB SENSOR HARNESS
I Front sub sensor harness (RH) circuit is shorted. (RH) INSPECTION
I Front sub sensor harness (RH) circuit is open.
I Front sub sensor (RH) is faulty. Measure resistance across test harness I or I2
I Airbag control module is faulty. connector (3I) terminal and chassis ground.
CAUTION: Connector & terminal
Before performing diagnostics on airbag (3I) No. 2 (+) — Chassis ground (−):
battery ground terminal, and then wait at least
20 seconds.
5K1 : FRONT SUB SENSOR (RH) AND

FRONT SUB SENSOR HARNESS
(RH) INSPECTION

test harness I or I2 connector (1I). B5M0555B

I2 connector (3I) terminal. : Is the resistance more than 10 kΩ?
Connector & terminal : Replace airbag control module. <Ref. to
(3I) No. 2 — No. 4: 5-5 [W5A0].>
: Go to step 5K3.
5K3 : FRONT SUB SENSOR (RH) AND

FRONT SUB SENSOR HARNESS
(RH) INSPECTION
Measure resistance across test harness I or I2

connector (3I) terminal and chassis ground.
B5M0554B (3I) No. 4 (+) — Chassis ground (−):
: Is the resistance between 750 Ω and

1 k Ω?
5-5 [W5A0].>
: Go to step 5K2.
B5M0556B
: Is the resistance more than 10 kΩ?

5-5 [W5A0].>
: Go to step 5K4.
27
5-5 [T5K4] DIAGNOSTICS
5K4 : AIRBAG MAIN HARNESS INSPEC- 5K6 : AIRBAG MAIN HARNESS INSPEC-
TION TION
1) Disconnect connector (AB14) and (AB15), then Measure resistance across test harness I or I2
connect test harness F connector (2F) and con- connector (3I) terminal and chassis ground.
nector (AB14). Connector & terminal
2) Measure resistance between test harness I or (3I) No. 2 (+) — Chassis ground (−):
I2 connector (3I) terminal and test harness F con-
nector (3F) terminal.
(3I) No. 2 — (3F) No. 6:
B5M0555B

: Go to step 5K7.
B5M0560B
5-5 [W4A0].>
: Is the resistance less than 10 Ω?
: Go to step 5K5.
5K7 : AIRBAG MAIN HARNESS INSPEC-
: Replace airbag main harness. <Ref. to TION
5-5 [W4A0].>
5K5 : AIRBAG MAIN HARNESS INSPEC- connector (3I) terminal and chassis ground.
TION
connector (3I) terminal and test harness F connec-
tor (3F) terminal.
(3I) No. 4 — (3F) No. 5:
B5M0556B

: Go to step 5K8.
B5M0561B
5-5 [W4A0].>
: Go to step 5K6.
5-5 [W4A0].>
28
DIAGNOSTICS [T5K10] 5-5
5K8 : FRONT SUB SENSOR HARNESS 5K9 : FRONT SUB SENSOR HARNESS
(RH) INSPECTION (RH) INSPECTION
1) Connect test harness F connector (1F) and Measure resistance between test harness F con-
connector (AB15). nector (3F) terminal and test harness H connector
2) Disconnect connector (AB16) from front sub (3H) terminal.
sensor (RH) <Ref. to 5-5 [W7A0].> and then test Connector & terminal
harness H connector (1H) and connector (AB16). (3F) No. 4 — (3H) No. 6:
3) Measure resistance between test harness F
connector (3F) terminal and test harness H con-
nector (3H) terminal.
(3F) No. 3 — (3H) No. 5:
B5M0563A

: Go to step 5K10.
: Replace front sub sensor harness (RH).
B5M0562A
<Ref. to 5-5 [W7A0].>
: Go to step 5K9. 5K10 : FRONT SUB SENSOR HARNESS
(RH) INSPECTION
<Ref. to 5-5 [W7A0].>
Measure resistance across test harness F connec-
tor (3F) terminal and chassis ground.
(3F) No. 3 (+) — Chassis ground (−):
B5M0564A

: Go to step 5K11.
<Ref. to 5-5 [W7A0].>
29
5-5 [T5K11] DIAGNOSTICS
5K11 : FRONT SUB SENSOR HARNESS 5K13 : FRONT SUB SENSOR (RH) INSPEC-
(RH) INSPECTION TION
Measure resistance across test harness F connec- Measure resistance across test harness H connec-
tor (3F) terminal and chassis ground. tor (3H) terminal and chassis ground.
Connector & terminal Connector & terminal
(3F) No. 4 (+) — Chassis ground (−): (3H) No. 3 (+) — Chassis ground (−):
B5M0565A B5M0567A
: Is the resistance more than 10 kΩ? : Is the resistance less than 10 kΩ?
: Go to step 5K12. : Go to step 5K14.
: Replace front sub sensor harness (RH). : Replace front sub sensor (RH). <Ref. to
5-5 [W7A0].>
<Ref. to 5-5 [W7A0].>
5K14 : FRONT SUB SENSOR (RH) INSPEC-

5K12 : FRONT SUB SENSOR (RH) INSPEC- TION
TION
Measure resistance across test harness H connec-

1) Connect test harness H connector (2H) and tor (3H) terminal and chassis ground.
front sub sensor (RH).
2) Measure resistance between test harness H Connector & terminal
connector (3H) terminal. (3H) No. 4 (+) — Chassis ground (−):
(3H) No. 3 — No. 4:
B5M0568A
: Is the resistance less than 10 kΩ?

B5M0566A
[T4C0].>
: Replace front sub sensor (RH). <Ref. to
1 k Ω? 5-5 [W7A0].>
: Go to step 5K13.
: Replace front sub sensor (RH). <Ref. to
5-5 [W7A0].>
30
DIAGNOSTICS [T5L3] 5-5
L: TROUBLE CODE 32 5L2 : FRONT SUB SENSOR (LH) AND

DIAGNOSIS: FRONT SUB SENSOR HARNESS (LH)
I Front sub sensor harness (LH) circuit is shorted. INSPECTION
I Front sub sensor harness (LH) circuit is open.
I Front sub sensor (LH) is faulty. Measure resistance across test harness I or I2
I Airbag control module is faulty. connector (3I) terminal and chassis ground.
CAUTION: Connector & terminal
Before performing diagnostics on airbag (3I) No. 1 (+) — Chassis ground (−):
20 seconds.
5L1 : FRONT SUB SENSOR (LH) AND

FRONT SUB SENSOR HARNESS (LH)
INSPECTION

test harness I or I2 connector (1I). B5M0558B

I2 connector (3I) terminal. : Is the resistance more than 10 kΩ?
Connector & terminal : Replace airbag control module. <Ref. to
(3I) No. 1 — No. 3: 5-5 [W5A0].>
: Go to step 5L3.
5L3 : FRONT SUB SENSOR (LH) AND

FRONT SUB SENSOR HARNESS (LH)
INSPECTION

connector (3I) terminal and chassis ground.
B5M0557B (3I) No. 3 (+) — Chassis ground (−):

1 k Ω?
5-5 [W5A0].>
: Go to step 5L2.
B5M0559B

5-5 [W5A0].>
: Go to step 5L4.
31
5-5 [T5L4] DIAGNOSTICS
5L4 : AIRBAG MAIN HARNESS INSPEC- 5L6 : AIRBAG MAIN HARNESS INSPEC-
TION TION
1) Disconnect connector (AB11) and (AB12), then Measure resistance across test harness I or I2
connect test harness F connector (2F) and con- connector (3I) terminal and chassis ground.
nector (AB11). Connector & terminal
2) Measure resistance between test harness I or (3I) No. 3 (+) — Chassis ground (−):
I2 connector (3I) terminal and test harness F con-
nector (3F) terminal.
(3I) No. 3 — (3F) No. 6:
B5M0559B

: Go to step 5L7.
B5M0569B
5-5 [W4A0].>
: Go to step 5L5.
5L7 : AIRBAG MAIN HARNESS INSPEC-
: Replace airbag main harness. <Ref. to TION
5-5 [W4A0].>
5L5 : AIRBAG MAIN HARNESS INSPEC- connector (3I) terminal and chassis ground.
TION
connector (3I) terminal and test harness F connec-
tor (3F) terminal.
(3I) No. 1 — (3F) No. 5:
B5M0558B

: Go to step 5L8.
B5M0570B
5-5 [W4A0].>
: Go to step 5L6.
5-5 [W4A0].>
32
DIAGNOSTICS [T5L10] 5-5
5L8 : FRONT SUB SENSOR HARNESS (LH) 5L9 : FRONT SUB SENSOR HARNESS (LH)
INSPECTION INSPECTION
1) Connect test harness F connector (1F) and Measure resistance between test harness F con-
connector (AB12). nector (3F) terminal and test harness H connector
2) Disconnect connector (AB13) from front sub (3H) terminal.
sensor (LH) <Ref. to 5-5 [W7A0].> and then test Connector & terminal
harness H connector (1H) and connector (AB13). (3F) No. 4 — (3H) No. 6:
3) Measure resistance between test harness F
connector (3F) terminal and test harness H con-
nector (3H) terminal.
(3F) No. 3 — (3H) No. 5:
B5M0563A

: Go to step 5L10.
: Replace front sub sensor harness (LH).
B5M0562A
<Ref. to 5-5 [W7A0].>
: Go to step 5L9. 5L10 : FRONT SUB SENSOR HARNESS
(LH) INSPECTION
<Ref. to 5-5 [W7A0].>
Measure resistance across test harness F connec-
tor (3F) terminal and chassis ground.
(3F) No. 3 (+) — Chassis ground (−):
B5M0564A

: Go to step 5L11.
<Ref. to 5-5 [W7A0].>
33
5-5 [T5L11] DIAGNOSTICS
5L11 : FRONT SUB SENSOR HARNESS 5L13 : FRONT SUB SENSOR (LH) INSPEC-
(LH) INSPECTION TION
Measure resistance across test harness F connec- Measure resistance across test harness H connec-
tor (3F) terminal and chassis ground. tor (3H) terminal and chassis ground.
(3F) No. 4 (+) — Chassis ground (−): (3H) No. 3 (+) — Chassis ground (−):
B5M0565A B5M0567A
: Is the resistance more than 10 kΩ? : Is the resistance less than 10 kΩ?
: Go to step 5L12. : Go to step 5L14.
: Replace front sub sensor harness (LH). : Replace front sub sensor (LH). <Ref. to
5-5 [W7A0].>
<Ref. to 5-5 [W7A0].>
5L14 : FRONT SUB SENSOR (LH) INSPEC-

5L12 : FRONT SUB SENSOR (LH) INSPEC- TION
TION
Measure resistance across test harness H connec-

1) Connect test harness H connector (2H) and tor (3H) terminal and chassis ground.
front sub sensor (LH).
2) Measure resistance between test harness H Connector & terminal
connector (3H) terminal. (3H) No. 4 (+) — Chassis ground (−):
(3H) No. 3 — No. 4:
B5M0568A
: Is the resistance less than 10 kΩ?

B5M0566A
[T4C0].>
: Replace front sub sensor (LH). <Ref. to
1 k Ω? 5-5 [W7A0].>
: Go to step 5L13.
: Replace front sub sensor (LH). <Ref. to
5-5 [W7A0].>
34
DIAGNOSTICS [T5M2] 5-5
M: AIRBAG WARNING LIGHT 5M2 : INSPECTION OF AIRBAG WARNING

REMAINS ON. LIGHT
DIAGNOSIS:
I Airbag warning light is faulty. 1) Turn ignition switch “OFF” and connect body
I Airbag control module to airbag warning light harness connector (B31) to test connector A con-
harness circuit is shorted or open. nector (1A).
I Grounding circuit is faulty.
I (AB1) and (B31) are not connected properly.
I (AB6) is not connected properly to airbag control
module.
CAUTION:
seconds.
S5M0282A
5M1 : CHECK POOR CONTACT IN CON- 2) Connect battery ground cable and turn ignition
NECTORS (AB1) AND (B31). switch “ON”, (engine off) and connect connectors
(3A) and (4A).
1) Remove front pillar lower trim (Driver side).
2) Check poor contact in connectors (AB1) and
(B31).
G5M0455
: Does the airbag warning light come

B5M0122B off?
: Go to step 5M4.
: Is there poor contact in double lock : Go to step 5M3.
of connectors (AB1) and (B31)?
: Repair poor contact in double lock of
connectors (AB1) and (B31).
: Go to step 5M2.
35
5-5 [T5M3] DIAGNOSTICS
5M3 : INSPECTION OF BODY HARNESS 5M5 : INSPECTION OF AIRBAG MAIN HAR-

NESS
Check body harness.
1) Turn ignition switch “OFF”, disconnect battery
NOTE:
ground cable and then wait at least 20 seconds,
After problem has been eliminated, disconnect
and re-connect connectors (AB1) and (B31).
connectors (3A) and (4A).
2) Remove instrument panel lower cover and dis-
connect (AB3) with (AB8), then disconnect con-
nector (AB6) from airbag control module, <Ref. to
5-5 [W5A0].> and connect it to test harness I or I2
connector (1I).
switch “ON”, (engine off) and connect connectors
(4I) and (5I).
NOTE:
After problem has been eliminated, disconnect
S5M0283A connectors (4I) and (5I).
: Is there anything unusual to body

harness?
: Repair body harness.
: Replace airbag warning light bulb <Ref.
to 6-2 [W8B0].> or combination meter
printed circuit.
5M4 : CHECK POOR CONTACT IN CON-

NECTOR (AB6). S5M0268B
Check connector (AB6) connected to airbag con- : Does the airbag warning light come
trol module. <Ref. to 5-5 [W5A0].> off?
: Is there poor contact in connector : Go to step 5M6.
(AB6)? : Replace airbag main harness. <Ref. to
: Repair poor contact in connector (AB6). 5-5 [W4A0].>
: Go to step 5M5.
36
DIAGNOSTICS [T5M9] 5-5
5M6 : GROUNDING CIRCUIT INSPECTION 5M8 : INSPECTION OF AIRBAG MAIN HAR-

NESS
ground cable and then wait at least 20 seconds. 1) Connect connectors (AB1) and (B31). Discon-
2) Disconnect connector (AB1) from body harness nect connector (AB6) from airbag control module
connector (B31), and connect connector (B31) to <Ref. to 5-5 [W5A0].>, and connect it to test har-
test harness A connector (1A). ness I or I2 connector (1I).
3) Measure resistance between connector (5A) 2) Measure resistance between each test harness
terminal and chassis ground. I or I2 connector (2I) terminal and chassis ground.
(5A) No. 17 (+) — Chassis ground (−): (2I) No. 9 (+) — Chassis ground (−):
S5M0271B
S5M0269A

: Go to step 5M9.
: Go to step 5M7.
: Repair body grounding circuit. 5-5 [W4A0].>
5M7 : GROUNDING CIRCUIT INSPECTION 5M9 : INSPECTION OF AIRBAG MAIN HAR-

NESS
Measure resistance between connector (5A) termi-
nal and chassis ground. Measure resistance between each test harness I
Connector & terminal or I2 connector (2I) terminal and chassis ground.
(5A) No. 18 (+) — Chassis ground (−): Connector & terminal
S5M0270A
S5M0272B
: Go to step 5M8. : Is resistance less than 10 Ω?
: Repair body grounding circuit. : Replace airbag control module. <Ref. to
5-5 [W5A0].>
5-5 [W4A0].>
37
5-5 [T5N0] DIAGNOSTICS
N: AIRBAG WARNING LIGHT 5N3 : AIRBAG WARNING LIGHT MODULE

REMAINS OFF. (IN COMBINATION METER) INSPEC-
TION
DIAGNOSIS:
I Body harness circuit is open. 1) Turn ignition switch “OFF”, disconnect battery
I Airbag warning light is faulty. ground cable and then wait at least 20 seconds.
I Airbag main harness is faulty. 2) Disconnect body harness connector (B31) from
I Airbag control module is faulty. connector (AB1).
CAUTION:
20 seconds.
5N1 : FUSE NO. 18 (IN JOINT BOX)

INSPECTION
Remove and visually check fuse No. 5 (In joint B5M0122B

box).
switch “ON” (engine off) to make sure airbag warn-
ing light illuminates.
S5M0257C

S5M0283A
: Replace fuse No. 18. If fuse No. 18
blows again, Go to step 5N2.
: Go to step 5N2. on?
: Go to step 5N4.
5N2 : BODY HARNESS INSPECTION
: Replace airbag warning light bulb <Ref.
to 6-2 [W8B0].> or combination meter
Turn ignition switch “ON” (engine off) to make sure printed circuit.
other warning lights (in combination meter) illumi-
nate.
: Do all the warning lights (in combina-
tion meter) except airbag warning
light come on?
: Go to step 5N3.
: Repair body harness.
38
DIAGNOSTICS [T5N4] 5-5
5N4 : AIRBAG MAIN HARNESS INSPEC-

TION

ground cable and then wait at least 20 seconds.
2) Connect body harness connector (B31) and
connector (AB1).
3) Disconnect connectors (AB3) and (AB8) below
steering column. <Ref. to 5-5 [M2F2].>
G5M0312

module. <Ref. to 5-5 [W5A0].>
switch “ON” to make sure airbag warning light illu-
minates.
on?
5-5 [W5A0].>
5-5 [W4A0].>
39
5-5 [T5O0] DIAGNOSTICS
O: WARNING LIGHT INDICATES 5O1 : AIRBAG COMPONENT PARTS

TROUBLE CODE, THEN NORMAL APPEARANCE INSPECTION
CODE. (FLASHING TROUBLE
CODE.) 1) Conduct on-board diagnostic and call up
trouble codes stored in memory. <Ref. to 5-5
DIAGNOSIS:
Airbag system component parts are faulty. [T4B0].>
2) Select trouble code required to check airbag
CAUTION: component parts from those listed in table and
Before performing diagnostics on airbag reproduce symptom.
battery ground cable, and then wait at least 20
seconds.
Trouble codes Check parts Index. No.

I Airbag module (Driver) <Ref. to 5-5 [W300].>
I Roll connector <Ref. to 5-5 [W600].>
5
I Airbag main harness <Ref. to 5-5 [W400].>
I Airbag control module <Ref. to 5-5 [W500].>
11
I Airbag module (Passenger) <Ref. to 5-5 [W300].>
12 I Airbag main harness <Ref. to 5-5 [W400].>
15
16 I Airbag module (Passenger) <Ref. to 5-5 [W300].>
21 Airbag control module <Ref. to 5-5 [W500].>
22 Airbag control module <Ref. to 5-5 [W500].>
I Fuse No. 6 <Ref. to 5-5 [T5J5].>
25
I Body harness <Ref. to 5-3 [W100].>
31
I Front sub sensor and front sub sensor harness (RH) <Ref. to 5-5 [W700].>
32
I Front sub sensor and front sub sensor harness (LH) <Ref. to 5-5 [W700].>
3) Conduct appearance inspection on parts

selected.
NOTE:
Also check connector terminals, wiring harness,
case, etc. for damage.
: Is there anything unusual about the
appearance of airbag component
parts?
: Replace faulty airbag component parts.
: Go to step 5O2.
40
DIAGNOSTICS [T5P2] 5-5
5O2 : AIRBAG COMPONENT PARTS P: WARNING LIGHT INDICATES

VIBRATION INSPECTION TROUBLE CODE, THEN NORMAL
CODE. (FLASHING NORMAL CODE.)
1) Gently shake check parts (to determine faults). DIAGNOSIS:
2) To check airbag module or roll connector, turn
I Airbag connector is faulty.
and tilt steering wheel.
CAUTION: I Airbag main harness is faulty.
Do not shake or vibrate airbag control module. I Airbag control module is faulty.
: Does the component malfunction I Body harness is faulty.
again when shaking? CAUTION:
: Replace faulty airbag component parts. Before performing diagnostics on airbag
: Go to step 5O3. system, turn ignition switch “OFF”, disconnect
battery ground cable, and then wait at least 20
5O3 : SHOWERING INSPECTION TO BODY seconds.
5P1 : AIRBAG CONNECTOR APPEARANCE

Spray water on vehicle body. INSPECTION
CAUTION:
Do not directly spray water on airbag compo- Conduct appearance inspection on airbag connec-
nents. tors (AB2) through (AB8). <Ref. to 5-5 [T100].>
NOTE: NOTE:
Also check wiring harnesses as water may leak Check terminals, case and wiring harnesses for
along them and get airbag component parts wet. damage.
: Is there anything unusual about the
appearance of connectors (AB2)
through (AB8)?
: Go to step 5P2.
5P2 : AIRBAG CONNECTOR VIBRATION

INSPECTION
G5M0461
Conduct vibration inspection on airbag connectors
: Does water leak into the passenger (AB2) through (AB8). <Ref. to 5-5 [T100].>
compartment when showering
NOTE:
vehicle?
Gently shake each airbag connector.
: Do the connectors (AB2) through
(AB8) malfunction again when shak-
[T4C0].>
ing?
: Go to step 5P3.
41
5-5 [T5P3] DIAGNOSTICS
5P3 : SHOWERING INSPECTION TO BODY 5P5 : FUSE NO. 11 (IN JOINT BOX), AIR-
BAG MAIN HARNESS, BODY HAR-
NESS VIBRATION INSPECTION
Spray water on vehicle body.
CAUTION:
Conduct vibration inspection on fuse No. 11, airbag
Do not directly spray water on airbag compo-
main harness and body harness.
nents.
CAUTION:
NOTE:
Do not shake or vibrate airbag control module.
If leaks are noted, also check wiring harnesses as
water may leak along them and wet airbag connec- NOTE:
tors. Gently shake each part.
: Do fuse No. 11, airbag main harness
or body harness malfunction again
when shaking?
: Go to step 5P6.
5P6 : SHOWERING INSPECTION TO BODY
Spray water on vehicle body.

G5M0461
CAUTION:
: Does water leak into the passenger Do not directly spray water on each part.
compartment when showering NOTE:
vehicle? If leaks are noted, check wiring harnesses as water
: Replace faulty airbag component parts. may leak along them and get parts wet.
: Go to step 5P4.
5P4 : FUSE NO. 11 (IN JOINT BOX), AIR-

BAG MAIN HARNESS, AIRBAG CON-
TROL MODULE, BODY HARNESS
APPEARANCE INSPECTION
Conduct appearance inspection on fuse No. 11

<Ref. to 5-5 [T5I5].>, airbag main harness <Ref. to
5-5 [W4A0].>, airbag control module <Ref. to 5-5 G5M0461
[W5A0].> and body harness.
NOTE: : Does water leak into the passenger
Also check connectors, terminals, wiring harness compartment when showering
and case for damage. vehicle?
: Is there anything unusual about the : Replace faulty airbag component parts.
appearance of fuse No. 11, airbag : Go to step 5P7.
main harness, airbag control module
or body harness?
: Go to step 5P5.
42
DIAGNOSTICS [T5P7] 5-5
5P7 : WARNING LIGHT ILLUMINATION

CHECK
Turn ignition switch “ON” (engine off) and observe

airbag warning light.
on for about 7 seconds, then go out
and stay out?
[T4C0].>
: Go to “DIAGNOSTICS PROCEDURE”.
<Ref. to 5-5 [T4D0].>
43
5-5 DIAGNOSTICS
MEMO:
44
1. Specifications
1. Specifications
Item Designation
Type Reduction type
MT AT
Model
M000T81681 M001T84481
Manufacturer MITSUBISHI
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
Voltage 11 V
No-load characteris- Current 90 A or less
tics Rotating
Starter 3,000 rpm or more
speed
Voltage 8V 7.7 V
Current 280 A or less 300 A or less
Load characteristics Torque 8.5 N·m (0.87 kg-m, 6.27 ft-lb) 9.8 N·m (1.00 kg-m, 7.24 ft-lb)
Rotating
980 rpm or more 1,000 rpm or more
speed
Voltage 4V
Current 780 A or less 980 A or less
Lock characteristics
17.6 N·m (1.80 kg-m, 13.0 ft-lb) or
Torque 23 N·m (2.3 kg-m, 17 ft-lb) or more
more
Type Rotating-field three-phase type, Voltage regulator built-in type
Model A2TB2991
Manufacturer MITSUBISHI
Voltage and output 12 V — 75 A
Polarity on ground side Negative
Generator Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
1,500 rpm — 30 A or more
Output current 2,500 rpm — 64 A or more
5,000 rpm — 76 A or more
Regulated voltage 14.5+0.3/−0.4 V [20°C (68°F)]
Model FH0137-01R
Manufacturer DEMCO
Ignition coil
Primary coil resistance 0.73 Ω±10%
and ignitor
assembly Secondary coil resistance 12.8 kΩ±15%
Insulation resistance between pri-
More than 10 MΩ
mary terminal and case
Standard RC10YC4 .......... CHAMPION
Type and manufac- RC8YC4 .......... CHAMPION
turer Alternate BKR6E-11 .......... NGK
Spark plug K20PR-U11 .......... NIPPONDENSO
Thread size 14, P = 1.25 mm
Spark gap 1.0 — 1.1 mm (0.039 — 0.043 in)
2
1. Starter
1. Starter
H6M0492B
(1) Sleeve bearing (7) Internal gear ASSY (13) Armature

(2) Front bracket (8) Shaft ASSY (14) Brush holder
(3) Lever set (9) Gear ASSY (15) Brush
(4) Magnet switch ASSY (10) Ball (16) Sleeve bearing
(5) Stopper set (11) Packing (17) Rear bracket
(6) Over running clutch (12) Yoke
3
2. Generator
2. Generator
H6M0493B
(1) Pulley (5) Rotor (9) Brush

(2) Front cover (6) Bearing (10) Rectifier
(3) Ball bearing (7) Stator coil (11) Rear cover
(4) Bearing retainer (8) IC regulator with brush (12) Terminal
4
3. Ignition System
3. Ignition System
S6M0329A
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kg-m, ft-lb)
(2) Spark plug cord (#1, #3)
T: 22±2 (2.2±0.2, 15.9±1.4)
(3) Ignition coil and ignitor ASSY
5
1. Starter
1. Starter 4) Remove starter from transmission.

1) Disconnect battery ground cable.
G2M0309
G6M0095
Tightening torque:
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
2) Remove air cleaner case and air intake duct.
<Ref. to 2-7 [W1A0].>
G2M0309
H2M2931
B: TEST
3) Disconnect connector and terminal from starter.
1. SWITCH ASSEMBLY OPERATION
1) Connect terminal S of switch assembly to posi-
tive terminal of battery with a lead wire, and starter
body to ground terminal of battery. Pinion should
be forced endwise on shaft.
CAUTION:
With pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.
S6M0002A
(A) Terminal
(B) Connector
6
1. Starter
2) Disconnect connector from terminal M, and 3. PERFORMANCE TEST

connect positive terminal of battery and terminal M
The starter should be submitted to performance
using a lead wire and ground terminal to starter
tests whenever it has been overhauled, to assure
body.
its satisfactory performance when installed on the
In this test set up, pinion should return to its origi-
engine.
nal position even when it is pulled out with a screw-
Three performance tests, no-load test, load test,
driver.
and lock test, are presented here; however, if the
load test and lock test cannot be performed, carry
out at least the no-load test.
For these performance tests, use the circuit shown
in figure.
G6M0029
2. PINION GAP
1) With pinion forced endwise on shaft, as outlined
G6M0031
in step 1) before <Ref. to 6-1 [W1B1].>, measure
pinion gap. 1) No-load test
Pinion gap: With switch on, adjust the variable resistance to
0.5 — 2.0 mm (0.020 — 0.079 in) obtain 11 V, take the ammeter reading and mea-
sure the starter speed. Compare these values with
the specifications.
No-load test (Standard):
Voltage / Current
11 V / 90 A or less
Rotating speed
I MT vehicles 2,800 rpm or more
I AT vehicles 2,400 rpm or more
2) Load test
G6M0030 Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
2) If motor is running with the pinion forced end- starter speed are within specifications.
wise on the shaft, disconnect connector from ter-
Load test (Standard):
minal M of switch assembly and connect terminal
M to ground terminal (−) of battery with a lead wire. I MT vehicles
Next, gently push pinion back with your fingertips Voltage / Load
and measure pinion gap. 7.5 V / 8.73 N·m (0.89 kg-m, 6.4 ft-lb)
3) If pinion gap is outside specified range, remove Current / Speed
or add number of adjustment washers used on the 300 A / 890 rpm or more
mounting surface of switch assembly until correct I AT vehicles
pinion gap is obtained. Voltage / Load
7.7 V / 16.00 N·m (1.63 kg-m, 11.8 ft-lb)
Current / Speed
400 A max. / 740 rpm or more
7
1. Starter
3) Lock test 4) Remove armature and yoke. Ball used as a

With starter stalled, or not rotating, measure the bearing will then be removed from the end of arma-
torque developed and current draw when the volt- ture.
age is adjusted to the specified voltage. CAUTION:
Lock test (Standard): Be sure to mark an alignment mark on yoke
I MT vehicles and front bracket before removing yoke.
Voltage / Load
4 V / 780 A or less
Torque
15.7 N·m (1.60 kg-m, 11.6 ft-lb) or more
I AT vehicles
Voltage / Current
3.5 V / 940 A or less
Torque
28.9 N·m (2.95 kg-m, 21.3 ft-lb) or more
C: DISASSEMBLY H6M0495A
1. STARTER ASSEMBLY 5) Remove packing A, three planetary gears,

packing B and plate.
1) Loosen nut which holds terminal M of switch
assembly, and disconnect connector.
2) Remove bolts which hold switch assembly, and
remove switch assembly, plunger and plunger
spring from starter as a unit.
CAUTION:
Be careful because pinion gap adjustment
washer may sometimes be used on the mount-
ing surface of switch assembly.
G6M0035
6) Remove shaft assembly and overrunning clutch

as a unit.
CAUTION:
Record the direction of lever before removing.
G6M0032
3) Remove both through-bolts and brush holder

screws, and detach rear bracket and brush holder.
G6M0036
H6M0494A
8
SERVICE PROCEDURE [W1D1] 6-1
1. Starter
7) Remove overrunning clutch from shaft assem- D: INSPECTION

bly as follows:
(1) Remove stopper from ring by lightly tapping 1. ARMATURE
a fit tool placed on stopper. 1) Check commutator for any sign of burns of
(2) Remove ring, stopper and clutch from shaft. rough surfaces or stepped wear. If wear is of a
minor nature, correct it by using sand paper.
2) Run-out test
Check the commutator run-out and replace if it
exceeds the limit.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in)
G6M0037
2. BRUSH HOLDER
Slightly open the metal fitting holding the insulating
plate to the brush holder. Remove the insulating
plate.
NOTE:
The brush and spring can be easily removed from
the brush holder at this time.
G6M0038
3) Depth of segment mold

Check the depth of segment mold.
Depth of segment mold:
0.5 mm (0.020 in)
H6M0497A
G6M0039
9
6-1 [W1D2] SERVICE PROCEDURE
1. Starter
4) Armature short-circuit test 4. BRUSH AND BRUSH HOLDER

Check armature for short-circuit by placing it on 1) Brush length
growler tester. Hold a hacksaw blade against Measure the brush length and replace if it exceeds
armature core while slowly rotating armature. A the service limit.
short-circuited armature will cause the blade to Replace if abnormal wear or cracks are noticed.
vibrate and to be attracted to core. If the hacksaw
blade is attracted or vibrates, the armature, which Brush length:
is short-circuited, must be replaced or repaired. Standard 17.0 mm (0.669 in)
Service limit 11.5 mm (0.453 in)
G6M0040
H6M0496A
5) Armature ground test 2) Brush movement

Using circuit tester, touch one probe to the com- Be sure brush moves smoothly inside brush
mutator segment and the other to shaft. There holder.
should be no continuity. If there is a continuity, 3) Brush spring force
armature is grounded. Measure brush spring force with a spring scale. If
Replace armature if it is grounded. it is less than the service limit, replace brush
spring.
Brush spring force:
Standard
21.6 N (2.2 kg, 4.9 lb) (when new)
Service limit
5.9 N (0.6 kg, 1.3 lb)
5. SWITCH ASSEMBLY
Be sure there is continuity between terminals S
and M, and between terminal S and ground. Use
G6M0041 a circuit tester (set in “ohm”).
Also check to be sure there is no continuity
2. YOKE between terminal M and B.
Terminal / Specified resistance:
Make sure pole is set in position.
S—M / Continuity
3. OVERRUNNING CLUTCH S—Ground / Continuity
M—B / No continuity
Inspect teeth of pinion for wear and damage.
Replace if it damaged. Rotate pinion in direction of
rotation (clockwise). It should rotate smoothly. But
in opposite direction, it should be locked.
CAUTION:
Do not clean overrunning clutch with oil to pre-
vent grease from flowing out.
G6M0044
10
2. Generator
E: ASSEMBLY 2. Generator
Assembly is in the reverse order of disassembly A: REMOVAL AND INSTALLATION
procedures. Observe the following:
1) Carefully assemble all parts in the order of 1) Disconnect battery ground cable.
assembly and occasionally inspect nothing has
been overlooked.
2) Apply grease to the following parts during
assembly.
I Front bracket sleeve bearing
I Armature shaft gear
I Outer periphery of plunger
I Mating surface of plunger and lever
I Gear shaft splines
I Mating surface of lever and clutch
I Ball at the armature shaft end G6M0095
I Internal and planetary gears
3) After assembling parts correctly, check to be 2) Disconnect connector and terminal from gen-
sure starter operates properly. erator.
S2M0941
3) Remove V-belt cover.
S2M0896
4) Remove front side V-belt.
G2M0286
11
2. Generator
5) Remove bolts which install generator onto 2) Hold rotor with a vise and remove pulley nut.
bracket.
G6M0066
H2M1499
CAUTION:
6) Installation is in the reverse order of removal. When holding rotor with vise, insert aluminum
CAUTION: plates or wood pieces on the contact surfaces
Check and adjust V-belt tension. <Ref. to 1-5 of the vise to prevent rotor from damage.
[G2A0].>
H6M0498A
H2M1499
3) Unsolder connection between rectifier and sta-
tor coil to remove stator coil.
B: DISASSEMBLY
CAUTION:
1) Remove the four through bolts. Then insert the Finish the work rapidly (less than three sec-
tip of a flat-head screwdriver into the gap between onds) because the rectifier cannot withstand
the stator core and front bracket. Pry then apart to heat very well.
disassemble.
G6M0068
G6M0065
12
2. Generator
4) Remove screws which secure IC regulator to C: INSPECTION AND REPAIR

rear cover, and unsolder connection between IC
regulator and rectifier to remove IC regulator. 1. DIODE
CAUTION:
Never use a megger tester (measuring use for
high voltage) or any other similar measure for
this test; otherwise, the diodes may be dam-
aged.
1) Checking positive diode
Check for continuity between the diode lead and
the positive side heat sink. The positive diode is in
good condition if continuity exists only in the direc-
G6M0069
tion from the diode lead to the heat sink.
5) Remove the brushes by unsoldering at the pig-

tails.
G6M0072
2) Checking negative diode

G6M0070 Check for continuity between the negative side
heat sink and diode lead. The negative diode is in
6) Remove the nut and insulating bushing at ter- good condition if continuity exists only in the direc-
minal B. Remove rectifier. tion from the heat sink to the diode lead.
G6M0071
G6M0073
2. ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any rough-
ness of the sliding surface. Repair slip ring surface
using a lathe or sand paper.
2) Slip ring outer diameter
Measure slip ring outer diameter. If slip ring is worn
replace rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
13
2. Generator
3) Continuity test 3. STATOR

Check resistance between slip rings using circuit 1) Continuity test
tester. If the resistance is not within specification, Inspect stator coil for continuity between each end
replace rotor assembly. of the lead wires. If there is no continuity between
Specified resistance: individual lead wires, the lead wire is broken, and
Approx. 2.7 — 3.2 Ω so replace stator assembly.
G6M0075 G6M0078
4) Insulation test 2) Insulation test

Check continuity between slip ring and rotor core Inspect stator coil for continuity between stator
or shaft. If continuity exists, the rotor coil is short- core and each end of the lead wire. If there is
continuity, the stator coil is short-circuited, and so
circuited, and so replace rotor assembly.
replace stator assembly.
G6M0076
G6M0079
5) Ball bearing (rear side)

(1) Check rear ball bearing. Replace if it is 4. BRUSH
noisy or if rotor does not turn smoothly. 1) Measure the length of each brush. If wear
(2) The rear bearing can be removed by using exceeds the service limit, replace the brush. Each
common bearing puller. brush has the service limit mark on it.
Brush length:
Standard
18.5 mm (0.728 in)
Service limit
5.0 mm (0.197 in)
G6M0077
H6M0499A
14
SERVICE PROCEDURE [W2D0] 6-1
2. Generator
2) Checking brush spring for proper pressure (3) Set a new bearing and closely install a fit
Using a spring pressure indicator, push the brush tool on the bearing outer race. Press the bear-
into the brush holder until its tip protrudes 2 mm ing down into place with a hand press or vise.
(0.08 in). Then measure the pressure of the brush A socket wrench can serve as the tool.
spring. If the pressure is less than 2.648 N (270 g, (4) Install front bearing retainer.
9.52 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.609 to
5.786 N (470 to 590 g, 16.58 to 20.81 oz).
G6M0145
D: ASSEMBLY
G6M0143
To assemble, reverse order of disassembly.
1) Pulling up brush
5. BEARING (FRONT SIDE) Before assembling, press the brush down into the
1) Check front ball bearing. If resistance is felt brush holder with your finger and secure in that
while rotating, or if abnormal noise is heard, position by passing a [2 mm (0.08 in) dia. length 4
replace the ball bearing. to 5 cm (1.6 to 2.0 in)] wire through the hole shown
2) Replacing front bearing in the figure.
(1) Remove front bearing retainer. CAUTION:
(2) Closely install a fit tool on the bearing inner Be sure to remove the wire after reassembly.
race. Press the bearing down out of front
bracket with a hand press or vise. A socket
wrench can serve as the tool.
G6M0146
2) Heat the rear bracket [50 to 60°C (122 to

140°F)] and press the rear bearing into the rear
G6M0144
bracket. Then lubricate the rear bracket.
CAUTION:
Grease should not be applied for the rear bear-
ing.
Remove oil completely if it is found on the
bearing box.
3) After reassembly, turn the pulley by hand to
check that the rotor turns smoothly.
15
3. Spark Plug
3. Spark Plug (3) Remove air intake duct as a unit.

CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
CHAMPION: RC10YC4
(Alternate)
CHAMPION: RC8YC4
NGK: BKR6E-11 B2M2012
NIPPONDENSO: K20PR-U11
(4) Remove resonator chamber.
1. #1 SPARK PLUG
B2M2306
G6M0095
3) Remove #1 spark plug cord by pulling boot, not
cord itself.
2) Remove air intake duct and resonator chamber.
(1) Remove bolt which installs air intake duct
on the front side of body.
B6M0922A
4) Remove spark plug with the spark plug socket.

S6M0708
(2) Remove bolt which installs air intake duct

on body.
B6M0923
B2M2284
16
3. Spark Plug
5) Installation is in the reverse order of removal. 3) Remove spark plug with the spark plug socket.
Tightening torque (Spark plug):
20.6±2.9 N·m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
Tightening torque (Resonator chamber):
32±10 N·m (3.3±1.0 kg-m, 24±7 ft-lb)
B6M0924

20.6±2.9 N·m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
B2M2306
CAUTION:
CAUTION: The above torque should be only applied to
The above torque should be only applied to new spark plugs without oil on their threads.
new spark plugs without oil on their threads. In case their threads are lubricated, the torque
In case their threads are lubricated, the torque should be reduced by approximately 1/3 of the
should be reduced by approximately 1/3 of the specified torque in order to avoid over-stress-
specified torque in order to avoid over-stress- ing.
ing. 3. #3 SPARK PLUG
2. #2 SPARK PLUG 1) Disconnect battery ground cable.
G6M0095
G6M0095 2) Remove air intake duct and resonator chamber.

2) Remove #2 spark plug cord by pulling boot, not (1) Remove bolt which installs air intake duct
cord itself. on the front side of body.
S6M0708
B6M0927A
17
3. Spark Plug
(2) Remove bolt which installs air intake duct 4) Remove spark plug with the spark plug socket.
on body.
B6M0925
B2M2284
(3) Remove air intake duct as a unit. Tightening torque (Spark plug):
20.6±2.9 N·m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
Tightening torque (Resonator chamber):
32±10 N·m (3.3±1.0 kg-m, 24±7 ft-lb)
B2M2012
(4) Remove resonator chamber.
B2M2306
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
B2M2306 ing.
3) Remove #3 spark plug cord by pulling boot, not 4. #4 SPARK PLUG
cord itself. 1) Disconnect battery ground cable.
B6M0928A
G6M0095
18
3. Spark Plug
2) Disconnect washer motor connector. 7) Installation is in the reverse order of removal.

20.6±2.9 N·m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
S2M0546 ing.
3) Disconnect rear window glass washer hose B: INSPECTION
from washer motor, then plug connection with a Check electrodes and inner and outer porcelain of
suitable cap. plugs, noting the type of deposits and the degree
4) Remove the two bolts which hold the washer of electrode erosion.
tank, then take the tank away from the working
area.
G6M0086
B2M2023 1) Normal
5) Remove #4 spark plug cord by pulling boot, not Brown to grayish-tan deposits and slight electrode
cord itself. wear indicate correct spark plug heat range.
B6M0929A G6M0087
6) Remove spark plug with the spark plug socket.
B6M0926
19
3. Spark Plug
2) Carbon fouled C: CLEANING AND REGAPPING

Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove car-
city, weak ignition, too rich fuel mixture, dirty air
bon or oxide deposits, but do not wear away por-
cleaner, etc.
celain.
It is advisable to replace with plugs having hotter If deposits are too stubborn, discard plugs.
heat range. After cleaning spark plugs, recondition firing sur-
face of electrodes with file. Then correct the spark
plug gap using a gap gauge.
Spark plug gap: L
1.0 — 1.1 mm (0.039 — 0.043 in)
G6M0088
3) Oil fouled
Wet black deposits show excessive oil entrance
into combustion chamber through worn rings and
pistons or excessive clearance between valve G6M0091
guides and stems. If same condition remains after
repair, use a hotter plug.
G6M0089
4) Overheating
White or light gray insulator with black or gray
brown spots and bluish burnt electrodes indicate
engine overheating. Moreover, the appearance
results from incorrect ignition timing, loose spark
plugs, wrong selection of fuel, hotter range plug,
etc. It is advisable to replace with plugs having
colder heat range.
G6M0090
20
4. Ignition Coil and Ignitor Assembly
4. Ignition Coil and Ignitor B: INSPECTION

Assembly Using accurate tester, inspect the following items,
and replace if defective.
A: REMOVAL AND INSTALLATION 1) Primary resistance
1) Disconnect battery ground cable. 2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:
[Primary side]
Between terminal No. 1 and No. 2
0.73 Ω±10%
Between terminal No. 2 and No. 4
0.73 Ω±10%
G6M0095
2) Disconnect spark plug cords from ignition coil

and ignitor assembly.
3) Disconnect connector from ignition coil and
ignitor assembly.
B6M0931A
[Secondary side]
Between (A) and (B)
12.8 kΩ±15%
Between (C) and (D)
B6M0932 12.8 kΩ±15%
4) Remove ignition coil and ignitor assembly.
B6M0773C
B6M0930 3) Insulation between primary terminal and case:

10 MΩ or more.
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
21
5. Spark Plug Cord
5. Spark Plug Cord

A: INSPECTION
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
#1 cord: 7.40 — 17.27
#2 cord: 6.24 — 14.56
#3 cord: 6.54 — 15.25
#4 cord: 6.59 — 15.37
S6M0337
22
1. Starter
1. Starter
Trouble Probable cause
Magnet switch poor contact or discontinuity of pull-in coil cir-
Magnet switch does not operate.
cuit
(no clicks are heard.)
Improper sliding of magnet switch plunger
Poor contact of magnet switch’s main contact point
Layer short of armature
Starter does not start.
Contaminants on armature commutator
Magnet switch operates.
High armature mica
(clicks are issued.)
Improper grounding of yoke field coil
Insufficient carbon brush length
Insufficient brush spring pressure
Worn pinion teeth
Failure of pinion gear to engage
Starter starts but does not Improper sliding of overrunning clutch
ring gear
crank engine. Improper adjustment of stud bolt
Clutch slippage Faulty clutch roller spring
Poor contact of magnet switch’s main contact point
Layer short of armature
Discontinuity, burning or wear of armature commutator
Starter starts but engine cranks too slowly. Poor grounding of yoke field coil
Insufficient brush length
Insufficient brush spring pressure
Abnormal brush wear
Starter overruns. Magnet switch coil is a layer short.
23
2. Generator
2. Generator
B6M0771
24
1. Body Electrical
1. Body Electrical
Reverse capacity MT model: 99 minutes AT model: 120 minutes
Battery Capacity
Cold cranking ampere MT model: 356 amperes AT model: 520 amperes
Speedometer Electric pulse type
Temperature gauge Thermistor cross coil type
Fuel gauge Resistance cross coil type
Tachometer Electric pulse type
Turn signal indicator light 12 V — 1.4 W
Charge indicator light 12 V — 1.4 W
Oil pressure indicator light 12 V — 1.4 W
ABS warning light 12 V — 1.4 W
Combination CHECK ENGINE warning light (Malfunction
12 V — 1.4 W
meter indicator light)
HI-beam indicator light 12 V — 1.4 W
Door open warning light 12 V — 1.4 W (LED)
Seat belt warning light 12 V — 1.4 W (LED)
Brake fluid and parking brake warning light 12 V — 1.4 W
FWD indicator light 12 V — 1.4 W
AIRBAG warning light 12 V — 1.4 W
Meter illumination light 12 V — 3.4 W, 3.0 W, 1.4 W
AT OIL TEMP. warning light 12 V — 1.4 W
Headlight 12 V — 60/55 W (Halogen)
Front fog light 12 V — 55 W
Front turn signal light 12 V — 27 W
Side turn signal light 12 V — 3.8 W
Side marker/Parking light 12 V — 3.8 W
Tail/Stop light 12 V — 8/27 W
Rear combination light Turn signal light 12 V — 27 W
Back-up light 12 V — 27 W
License plate light 12 V — 3.8 W
High-mount stop light Sedan: 12 V — 18 W Wagon: 12 V — 13 W
Room light 12 V — 8 W
Spot light 12 V — 8 W
Trunk room light 12 V — 5 W
Luggage room light 12 V — 5 W
Front wiper motor Input 12 V — 54 W or less
Rear wiper motor Input 12 V — 42 W or less
Front washer Pump type Centrifugal
motor Input 12 V — 36 W or less
Rear washer Pump type Centrifugal
motor Input 12 V — 36 W or less
Horn 12 V — 350 Hz
Accessory socket Input 12 V — 120 W
Rear window Input 12 V — 160 W
defogger Indicator light 12 V — 50 mA
Cargo socket Input 12 V — 120 W
2
2. Battery
1. Precautions 2. Battery
I Before disassembling or reassembling parts, A: REMOVAL AND INSTALLATION
always disconnect battery ground cable. When
repairing radio, control units, etc. which are 1) Disconnect the positive (+) terminal after dis-
provided with memory functions, record connecting the negative (− ) terminal of battery.
memory contents before disconnecting battery 2) Remove flange nuts from battery rods and take
ground cable. Otherwise, these contents are off battery holder.
cancelled upon disconnection.
I Reassemble parts in reverse order of disas-
sembly procedure unless otherwise indicated.
I Adjust parts to specifications contained in
this manual if so designated.
I Connect connectors and hoses securely dur-
ing reassembly.
I After reassembly, ensure functional parts
operate smoothly.
CAUTION:
I Airbag system wiring harness is routed near G6M0102
the electrical parts and switch.
I All Airbag system wiring harness and con- 3) Remove battery.
nectors are colored yellow. Do not use electri- 4) Installation is in the reverse order of removal.
cal test equipment on these circuits. Tightening torque:
I Be careful not to damage Airbag system wir- 3.4±1.0 N·m (0.35±0.1 kg-m, 2.5±0.7 ft-lb)
ing harness when servicing the ignition key
cylinder. NOTE:
I Clean battery cable terminals and apply grease
to retard the formation of corrosion.
I Connect the positive (+) terminal of battery and
then the negative (− ) terminal of the battery.
B: INSPECTION
WARNING:
I Electrolyte has toxicity; be careful handling
the fluid.
I Avoid contact with skin, eyes or clothing.
Especially at contact with eyes, blush with
water for 15 minutes and get prompt medical
attention.
I Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
I Ventilate when charging or using in enclosed
space.
I For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a
battery.
I Do not let battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
corrosive acid.
I To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle
because a short circuit will be caused.
3
2. Battery
1. BATTERY I Observe instructions when handling battery

charger.
1) External parts: I Before charging the battery on vehicle, dis-
Check for the existence of dirt or cracks on the connect battery ground terminal. Failure to fol-
battery case, top cover, vent plugs, and terminal low this rule may damage alternator’s diodes
posts. If necessary, clean with water and wipe with or other electrical units.
a dry cloth. Apply a thin coat of grease on the ter-
minal posts to prevent corrosion. 1. NORMAL CHARGING
2) Electrolyte level: Charge the battery at current value specified by
Check the electrolyte level in each cell. If the level manufacturer or at approximately 1/10 of battery’s
is below MIN LEVEL, bring the level to MAX ampere-hour rating.
LEVEL by pouring distilled water into the battery
cell. Do not fill beyond MAX LEVEL. 2. QUICK CHARGING
3) Specific gravity of electrolyte: Quick charging is a method in which the battery is
(1) Measure specific gravity of electrolyte using charged in a short period of time with a relatively
a hydrometer and a thermometer. Specific grav- large current by using a quick charger. Since a
ity varies with temperature of electrolyte so that large current flow raises electrolyte temperature,
it must be corrected at 20°C (68°F) using the the battery is subject to damage if the large current
following Equation: is used for prolonged time. For this reason, the
S20 = St + 0.0007 x (t − 20) quick charging must be carried out within a current
S20:Specific gravity corrected at electro- range that will not increase the electrolyte tem-
lyte temperature of 20°C perature above 40°C (104°F). It should be also
St :Measured specific gravity remembered that the quick charging is a temporary
t :Measured temperature (°C) means to bring battery voltage up to a fair value
Determine whether or not battery must and, as a rule, a battery should be charged slowly
be charged, according to corrected spe- with a low current.
cific gravity. CAUTION:
Standard specific gravity: 1.220 — 1.290 I Observe the items in 1. NORMAL CHARG-
[at 20°C (68°F)] ING.
I Never use more than 10 amperes when
charging the battery because that will shorten
battery life.
3. JUDGMENT OF BATTERY IN
CHARGED CONDITION
1) Specific gravity of electrolyte is held at a spe-
cific value in a range from 1.250 to 1.290 for more
than one hour.
2) Voltage per battery cell is held at a specific
G6M0103 value in a range from 2.5 to 2.8 volts for more than
one hour.
(2) Measuring the specific gravity of the elec-
trolyte in the battery will disclose the state of 4. CHECK HYDROMETER FOR STATE OF
charge of the battery. The relation between the CHARGE
specific gravity and the state of charge is as
shown in figure. Hydrometer indi-
State of charge Required action
cator
C: CHARGING Green dot Above 65% Load test
Dark dot Below 65% Charge battery
WARNING:
Replace battery*
I Do not bring an open flame close to the bat- Clear dot Low electrolyte (If cranking com-
tery at this time. plaint)
CAUTION: *: Check electrical system before replacement.
I Prior to charging, corroded terminals should
be cleaned with a brush and common baking
soda solution.
I Be careful since battery electrolyte over-
flows while charging the battery.
4
4. Lighting
3. Ignition Switch 4. Lighting

A: REMOVAL AND INSTALLATION A: ADJUSTMENT
1) Remove screws, separate upper column cover 1. HEADLIGHT AIMING
and lower column cover.
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check
aiming, do not turn on for more than two min-
utes.
NOTE:
Before checking the headlight aiming, be sure of
the following:
I The area around the headlight has not sustained
any accident, damage or other type of deformation.
G6M0104 I Vehicle is parked on level ground.
I The inflation pressure of tires is correct.
2) Remove knee protector.
I Vehicle’s gas tank is fully charged.
3) Remove meter visor.
4) Disconnect ignition switch connector from body I Bounce the vehicle several times to normalize
harness. the suspension.
5) Using a drift and hammer, hit the torn bolt head I Make certain that someone is seated in the driv-
to loosen and remove the ignition switch. er’s seat.
G6M0020

NOTE:
When installing, tighten the connecting bolt until its
head twists off.
G6M0105
5
4. Lighting
1) Place a cloth over the headlight that does not B: REMOVAL AND INSTALLATION
require aiming adjustment.
2) Turn the headlights on. Perform the aiming 1. HEADLIGHT BULB
adjustment for the other headlight as follows: 1) Disconnect the connector from inside of the
CAUTION: engine compartment.
Do not perform lateral headlight aiming adjust- 2) Remove rubber cap.
ment. 3) Remove the light bulb retaining spring to
remove the bulb.
H6M0400
4) Replace the bulb with a new one and hook the

spring.
5) Attach the rubber cap and connect the connec-
tor.
CAUTION:
I Since the tungsten halogen bulb operates at
high temperature, dirt and oil on the bulb sur-
face decreases the bulb’s useful life. When
replacing the bulb, hold the flange portion and
H6M0709A
do not touch the glass portion.
W H L h
Except 1,070 mm 630 mm 712 mm 114 mm
OUTBACK (42.13 in) (24.80 in) (28.03 in) (4.49 in)
1,070 mm 650 mm 712 mm 114 mm
OUTBACK
(42.13 in) (25.59 in) (28.03 in) (4.49 in)
M6A0139
I Attach the rubber cap with letters TOP on the

top so that the drain hole will be on the lower
side.
M6A0140
6
4. Lighting
I To keep water out, correctly engage the 3) Attach adhesive cloth tape to body area around
groove portion of the rubber cap. rear combination light.
4) Using a standard screwdriver, carefully pry rear
2. HEADLIGHT AND SIDE MARKER LIGHT combination light off and away from the front of
1) Remove front grille and disconnect connector vehicle.
from headlight. 5) Installation is in the reverse order of removal.
2) Remove screw then remove side marker light Tightening torque:
while disconnecting connector. 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
CAUTION:
I Do not pry rear combination light forcefully
as this may scratch vehicle body.
I Remove all traces of adhesive tape from
body before installation.
I Attach butyl rubber tape to back of rear com-
bination light before installing rear combina-
tion light on body for sealing purposes.
4. COMBINATION SWITCH
H6M0398
1) Remove instrument panel lower cover. <Ref. to
3) Remove screws and bolts which secure head- 5-4 [W1A0].>
light and remove headlight. 2) Remove screws which secure upper column
cover to lower column cover.
H6M0399
S6M0042
3) Disconnect connector from combination switch.
Tightening torque:
4) Remove screws which secure switch and
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
remove switch.
NOTE:
When installing, securely fit clip (on fender side)
into locating (on side marker light side).
3. REAR COMBINATION LIGHT
1) Remove rear trim.
2) Remove nuts and disconnect connector.
S6M0046
G6M0097
7
4. Lighting
C: INSPECTION 2. HEADLIGHT RELAY

1. COMBINATION SWITCH (LIGHTING) Check continuity between terminals when terminal
No. 4 is connected to battery and terminal No. 3 is
Move combination switch to respective positions grounded.
and check continuity between terminals.
When current Between terminals
Continuity exists.
flows. No. 1 and No. 2
Between terminals Continuity does
When current No. 1 and No. 2 not exist.
does not flow. Between terminals
Continuity exists.
No. 3 and No. 4
S6M0048A
3. TAIL AND ILLUMINATION RELAY

Check continuity between terminals (indicated in
table) when terminal No. 4 is connected to battery
H6M0500B
and terminal No. 3 is grounded.
When current Between terminals
Continuity exists.
flows. No. 1 and No. 2
Between terminals Continuity does
When current No. 1 and No. 2 not exist.
does not flow. Between terminals
Continuity exists.
No. 3 and No. 4
S6M0048A
S6M0136A
8
5. Front Wiper and Washer
5. Front Wiper and Washer B: REMOVAL AND INSTALLATION

A: ADJUSTMENT 1. BLADE
1) Turn the wiper switch to OFF position. 1) Pull out blade following the arrow direction,
from arm while pushing up locking clip.
2) Adjust blades in original position as shown in
figure by changing wiper arm installation.
Original position:
A: 22.5±7.5 mm (0.886±0.295 in)
B: 32.5±7.5 mm (1.280±0.295 in)
B6M0107A

2. WIPER ARM
G6M0115
1) Open front hood.
2) Remove cap. Remove the nut which secure
3) Adjust washer ejecting area on windshield wiper arm, and remove wiper arm.
glass as shown in figure when vehicle stops.
Ejecting area:
A: 400 mm (15.75 in)
B: 150 mm (5.91 in)
C: 100 mm (3.97 in)
G6M0118

NOTE:
Remove metal sludge from the wiper arm fixture
before installing it.
B6M1315A
Tightening torque:
20±3 N·m (2.0±0.3 kg-m, 14.4±2.2 ft-lb)
9
3. WIPER MOTOR AND LINK 5) Remove wiper link from service hole in front
panel.
1) Detach weatherstrip and cowl panel. <Ref. to
5-1 [W12A0].>
NOTE:
Apply silicone oil or soap water to both sides of
cowl net to facilitate removal.
2) Disconnect electric connector, and remove
motor attaching bolts.
Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
G6M0121
G6M0119
3) Remove nut securing motor link on the back

side of motor.
Tightening torque:
15±3 N·m (1.5±0.3 kg-m, 10.8±2.2 ft-lb)
G6M0120
4) Remove nuts which secure sleeve unit.

Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
G6M0021
10
C: INSPECTION 2. WIPER MOTOR

1. COMBINATION SWITCH (ON-CAR) 1) Check wiper motor operation at low speed:
Connect battery to wiper motor. Check wiper motor
Set wiper switch to each position and check conti- for proper operation at low speed.
nuity between terminals.
G6M0122
2) Check wiper motor operation at high speed:

Connect battery wiper motor. Check wiper motor
for proper operation at high speed.
H6M0501B
G6M0123
3) Check wiper motor for proper stoppage:

Connect battery to wiper motor. After operating
wiper motor at low speed, disconnect battery to
stop it.
G6M0124
S6M0137
11
6. Rear Wiper and Washer
4) Reconnect battery and ensure that wiper motor 6. Rear Wiper and Washer
stops at “AUTO STOP” after operating at low
speed. A: ADJUSTMENT
1) Adjust wiper blade in original position as shown
in figure by changing wiper arm installation.
Original position:
A: 30±5 mm (1.18±0.20 in)
G6M0125
G6M0126
2) Adjust washer ejecting point on rear gate win-

dow as shown in figure when the vehicle stops.
Ejecting point:
A: 25 mm (0.98 in)
B: 200 — 300 mm (7.87 — 11.81 in)
G6M0127
B: REMOVAL AND INSTALLATION

1. BLADE
1) Pull out blade following the arrow direction,
from arm while pushing up locking clip.
B6M0107A
12
2. WIPER ARM 5) Remove attaching screws and take out wiper

motor assembly.
1) Remove head cover.
2) Remove nut and wiper arm. CAUTION:
Be careful not to damage O-ring when remov-
ing wiper motor assembly.
G6M0128
3) Installation is in the reverse order of removal. G6M0130
NOTE:
Remove metal sludge from the wiper arm fixture 6) Installation is in the reverse order of removal.
before installing it. Tightening torque:
Tightening torque: 5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb) 4. WASHER TANK
3. WIPER MOTOR 1) Remove rear quarter trim.
1) Remove cap and special nut. 2) Disconnect washer hose and connector.
3) Remove attaching bolts.
CAUTION:
Be careful not to strike service tool against
nozzle during removal.
Tightening torque:
7.4±1.5 N·m (0.75±0.15 kg-m, 5.4±1.1 ft-lb)
G6M0022

Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
G6M0129
2) Remove rear gate trim. <Ref. to 5-2 [W3A0].>

3) Undo clips which secure harness, and discon-
nect connector of wiper motor.
4) Separate washer hoses at joint.
13
C: INSPECTION 2) Check wiper motor for proper stoppage:

After operating wiper motor, disconnect battery
1. COMBINATION SWITCH (ON-CAR) from wiper motor.
Set rear wiper and washer switch to each position
and check continuity between terminals.
G6M0132
3) Reconnect battery and ensure that wiper motor

H6M0502B
stops at “AUTO STOP” after it has been operated.
G6M0133
S6M0137
2. WIPER MOTOR
1) Operational check:
Connect battery to wiper motor and check opera-
tion of wiper motor.
G6M0131
14
7. Rear Window Defogger
3. REAR WIPER RELAY 7. Rear Window Defogger

1) Connect battery to terminal No. 1 and ground
terminal No. 2. A: INSPECTION
2) Check continuity between terminals. 1. HEAT WIRES
Between terminals Continuity does 1) Start the engine so that battery is being
When current No. 3 and No. 4 not exist. charged.
flows. Between terminals 2) Turn defogger switch ON.
Continuity exists.
No. 3 and No. 5 3) Check each heat wire at its center position for
Between terminals
Continuity exists.
discontinuity by setting direct current voltmeter.
No. 3 and No. 4
NOTE:
When current Between terminals Continuity does
does not flow. No. 3 and No. 5 not exist.
I Normal indication is about 6 volts.
Between terminals
Continuity exists.
No. 1 and No. 2
G6M0135
I When measuring voltage, wind a piece of tin foil

around the tip of the tester probe and press the foil
against the wire with your finger.
S6M0075A
G6M0136
15
7. Rear Window Defogger
4) When tester indicates 12 volts when its probe B: REPAIR

reaches point “A”, a broken circuit occurs between
point “A” and the negative terminal. Slowly move 1) Clean broken wire and its surrounding area.
tester probe toward the negative terminal while 2) Cut off slit on (used) thin film by 0.5 mm (0.020
contacting it on heat wire to locate point where in) width and 10 mm (0.39 in) length.
tester indication changes abruptly (0 volts). This is 3) Place the slit on glass along the broken wire,
the point where a broken circuit occurs. When and deposit conductive silver composition
tester indicates 0 volts when its probe reaches (DUPONT No. 4817) on the broken portion.
point “A”, a broken circuit occurs between point “A”
and the positive terminal. Locate a point where
tester indication changes abruptly (12 volts) while
slowly moving tester probe toward the positive ter-
minal.
G6M0138
4) Dry out the deposited portion.

5) Inspect the repaired wire for continuity.
G6M0137
16
8. Combination Meter
8. Combination Meter B: BULB REPLACEMENT

1) Move steering wheel most down.
2) Remove screws which secure visor and
remove visor.
H6M0780A
(1) Speedometer and tachometer

(2) HI-beam
(3) Turn RH
(4) Turn LH
H6M0522A (5) Airbag
(6) Clock
3) Remove screws which secure combination (7) Fuel and temperature gauge
meter, and pull combination meter out. (8) ABS
(9) Low fuel
(10) FWD
(11) AT oil temp.
(12) Speedometer
(13) Check engine
(14) Charge
(15) Tachometer
(16) Brake
(17) Oil pressure
H6M0523
4) Disconnect connector from back of combination

meter.
CAUTION:
When installing combination meter, be sure to
connect connectors to backside of combina-
tion meter.
17
9. Radio, Speaker and Antenna
9. Radio, Speaker and Antenna 10. Front Fog Light

1. RADIO BODY 1) Disconnect ground cable from battery.
2) Remove front fog light cover.
1) Remove console box. <Ref. to 5-4 [W1A0].>
2) Remove AT cover (AT model).
3) Remove center panel.
4) Remove fitting screws, and slightly pull radio
out from center console.
H6M0525
3) Remove the two screws, then draw out the front

fog light from front bumper.
S5M0048A
5) Disconnect electric connectors and antenna

feeder cord.
2. FRONT SPEAKER
1) Remove front door trim and disconnect connec-
tor. <Ref. to 5-2 [W2A2].>
2) Remove screws which secure front speaker.
3) Remove speaker and disconnect connector. H6M0526
4) Installation is in the reverse order of removal. 4) Disconnect the connector.

3. REAR SPEAKER (SEDAN) 5) Installation is in the reverse order of removal.
1) Remove rear shelf trim panels.
2) Remove screws which secure rear speakers.
3) Disconnect connector and remove speakers.
4. REAR SPEAKER (WAGON)
1) Remove rear door trim and disconnect connec-
tor. <Ref. to 5-2 [W2A2].>
2) Remove screws which secure rear speaker.
3) Remove speaker and disconnect connector.
18
11. Cruise Control
11. Cruise Control

A: ADJUSTMENT
S6M0138A
19
11. Cruise Control
B: REMOVAL AND INSTALLATION 5) Disconnect cruise control vacuum hose from

intake manifold.
1. ACTUATOR
1) Remove air intake chamber.
S6M0089
6) Remove actuator attaching bolts.

S6M0007
7) Disconnect connector from actuator, then
2) Remove air intake chamber stay. remove the actuator.
3) Remove clip bands from cruise control cable.
S6M0090
S6M0087
4) Remove cruise control cable end from throttle Tightening torque:
cam. 7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
CAUTION:
When inserting vacuum hose to intake
manifold, apply sealant to the fitting hose.
Fluid packing:
THREE BOND 1105 or equivalent
CAUTION:
I Be careful not to apply excessive load to the
wire cable when adjusting and/or installing;
otherwise, the actuator may be deformed or
S6M0088
damaged.
I Do not bend cable sharply with a radius less
than 100 mm (3.94 in); otherwise, cable may
bend permanently, resulting in poor perfor-
mance.
I When installing cable, be careful not to
sharply bend or pinch the inner cable;
otherwise, the cable may break.
20
11. Cruise Control
2. CRUISE CONTROL MAIN SWITCH 4) Using TORXT BIT T30 (Tamper resistant type),
remove two TORXT bolts which secure driver’s air-
1) Remove screws and clip from instrument panel
bag module.
lower cover.
2) Remove panel lower cover.
S6M0094A
S6M0091 5) Disconnect airbag module connector on back of

airbag module.
3) Disconnect connector from cruise control main
6) Remove horn switch from steering wheel as
switch.
shown.
S6M0092A
S6M0095
4) Remove main switch by pushing it outward.

7) Disconnect horn and cruise control command
switch connector, then remove cruise control com-
mand switch.
S6M0093

S6M0096
3. CRUISE CONTROL COMMAND SWITCH
CAUTION:
Before starting operation carefully read the
notes given in Chapter 5-5 for proper handling
of the airbag module. <Ref. to 5-5 [W3A0].>
2) Turn ignition switch OFF.
3) Disconnect battery ground cable from battery
and wait for at least 20 seconds before starting
work.
21
11. Cruise Control
4. CRUISE CONTROL MODULE

1) Remove front pillar lower trim.
S6M0097
2) Disconnect connector from cruise control mod-

ule.
3) Remove bolt, then remove cruise control mod-
ule.
S6M0098

5. STOP AND BRAKE SWITCH
Disconnect connector from switch, then remove
the switch. <Ref. to 4-5 [C100].>
6. CLUTCH SWITCH
Disconnect connector from switch, then remove
the switch. <Ref. to 4-5 [C100].>
22
DIAGNOSTICS [K1A0] 6-2
1. AT Shift Lock System

A: BASIC DIAGNOSTICS CHART
H6M0504
23
6-2 [K1B0] DIAGNOSTICS
B: DIAGNOSTICS PROCEDURE NO. 1
H6M0505
24
DIAGNOSTICS [K1C0] 6-2
C: DIAGNOSTICS PROCEDURE NO. 2 (SHIFT LOCK DOES NOT RELEASE.)
H6M0506
25
6-2 [K1D0] DIAGNOSTICS
D: DIAGNOSTICS PROCEDURE NO. 3 (KEY INTERLOCK DOES NOT

OPERATE.)
H6M0507
26
DIAGNOSTICS [K1E0] 6-2
E: DIAGNOSTICS PROCEDURE NO. 4 (KEY INTERLOCK DOES NOT

RELEASE.)
H6M0508
27
6-2 [K2A0] DIAGNOSTICS
2. Combination Meter 2A2 : CHECK GROUND CIRCUIT OF COM-

BINATION METER.
A: DIAGNOSTICS PROCEDURE
If speedometer does not operate, or operates 1) Turn ignition switch to OFF.
abnormally, check combination meter circuit. 2) Measure resistance of harness between com-
CAUTION: bination meter connector and chassis ground.
Make sure that trouble code of vehicle speed Connector & terminal
sensor 2 system appears in electrical system (i12) No. 13 (+) — Chassis ground (−):
on-board diagnosis.
2A1 : CHECK POWER SUPPLY FOR COM-

BINATION METER.
1) Remove combination meter.

2) Turn ignition switch to ON.
3) Measure voltage between combination meter
connector and chassis ground.
H6M0777A
(i12) No. 7 (+) — Chassis ground (−):
: Go to step 2A3.
: Repair harness and connector.
2A3 : CHECK TRANSMISSION TYPE.
: Is the transmission type MT?

: Go to step 2A4.
H6M0776A
: Go to step 2A8.
: Is the voltage more than 10 V?
: Go to step 2A2.
: Repair harness and connector.
NOTE:
In this case, repair the following:
I Open circuit in harness between combination
meter and battery.
I Poor contact in coupling connectors (i12) and
combination meter connector. <Ref. to FORE-
WORD [T3C0].>
28
2A4 : CHECK HARNESS CONNECTOR 2A6 : CHECK HARNESS CONNECTOR

BETWEEN COMBINATION METER BETWEEN VEHICLE SPEED SENSOR
AND VEHICLE SPEED SENSOR 2. 2 AND ENGINE GROUND.
1) Disconnect connector from vehicle speed sen- 1) Turn ignition switch to OFF.
sor 2. 2) Measure resistance between vehicle speed
2) Measure resistance of harness connector sensor 2 connector (B17) and engine ground.
between vehicle speed sensor 2 and combination Connector & terminal
meter. (B17) No. 2 (+) — Engine ground (−):
(B17) No. 1 — (i12) No. 10:
B6M0946A
H6M0778A : Is the resistance less than 10 Ω?

: Go to step 2A7.
: Repair harness connector between
: Go to step 2A5. vehicle speed sensor 2 and engine
: Repair wiring harness. ground.
2A5 : CHECK HARNESS CONNECTOR

BETWEEN BATTERY AND VEHICLE
SPEED SENSOR 2.

2) Measure voltage between vehicle speed sensor
2 connector (B17) and chassis ground.
(B17) No. 3 (+) — Chassis ground (−):
B6M0945A

: Go to step 2A6.
: Repair harness connector between bat-
tery and vehicle speed sensor 2.
29
6-2 [K2A7] DIAGNOSTICS
2A7 : CHECK VEHICLE SPEED SENSOR 2. 2A8 : CHECK HARNESS CONNECTOR

BETWEEN COMBINATION METER
AND AUTOMATIC TRANSMISSION
1) Connect connector to vehicle speed sensor 2.
CONTROL MODULE.
2) Set the vehicle on free roller, or lift-up the
vehicle and support with safety stands.
1) Disconnect connector from automatic transmis-
WARNING:
sion control module.
Be careful not to be caught up by the running
2) Measure resistance between combination
wheels.
meter connector (i12) and automatic transmission
3) Set oscilloscope to vehicle speed sensor 2 con- control module connector (B55).
nector terminals.
CAUTION:
Positive probe; (B17) No. 1
To measure the voltage and/or resistance, use
Earth lead; (B17) No. 2
a tapered pin with a diameter of less than 0.64
mm (0.025 in). Do not insert the pin more than
5 mm (0.20 in).
(i12) No. 10 — (B55) No. 13:
H6M0789A
4) Drive the vehicle at speed greater than 20 km/h

(12 MPH).
5) Measure signal voltage indicated on oscillo-
scope. H6M0779A

: Go to step 2A9.
combination meter and automatic trans-
mission control module.
H6M0790A

: Repair or replace speedometer.
: Replace vehicle speed sensor 2.
30
2A9 : CHECK AUTOMATIC TRANSMISSION

CONTROL MODULE.
1) Connect connector to automatic transmission

control module.
WARNING:
Be careful not to be caught by the running
wheels.
3) Drive the vehicle faster than 10 km/h (6 MPH).
4) Measure voltage between automatic transmis-
sion control module connector (B55) and chassis
ground.
CAUTION:
5 mm (0.20 in).
B6M0949A
: Is the voltage less than 1 V ←→ more

than 4 V?
: Repair or replace speedometer.
: Replace automatic transmission control
module. <Ref. to 3-2 [W2300].>
31
6-2 DIAGNOSTICS
MEMO:
32
1. Precaution
1. Precaution 2. Pre-inspection
A: SUPPLEMENTAL RESTRAINT A: FUNCTION TESTS
SYSTEM “AIRBAG” Conduct road tests by selecting a smooth, flat road
Airbag system wiring harness is routed near the or use free rollers for road test simulation.
cruise control module and cruise control command
switch. 1. CRUISE CONTROL MAIN SWITCH
CAUTION: 1) Turn ignition switch to ON.
I All Airbag system wiring harness and con- 2) Check that cruise control main switch indicator
nectors are colored yellow. Do not use electri- light comes on when main switch is pressed (ON).
cal test equipment on these circuits. 3) Check that main switch indicator light goes out
I Be careful not to damage Airbag system wir- when main switch is pressed again (OFF).
ing harness when servicing the cruise control 4) Turn ignition switch to OFF with main switch ON
module and cruise control command switch. (indicated by illumination). Turn ignition switch ON
again to ensure that main switch indicator light
remains OFF.
2. CRUISE CONTROL COMMAND SWITCH
1) Check that cruise control command switch is
properly set in “SET/COAST”, “RESUME/ACCEL”,
or “CANCEL” mode.
2) Also check that command switch returns to the
original position when released.
3. CONSTANT SPEED TEST
1) Turn cruise control main switch to ON.
2) Drive the vehicle at a speed greater than 40
km/h (25 MPH).
3) Press command switch to set in “SET/COAST”
mode.
4) Ensure that vehicle is maintained at the speed
set when command switch was pressed.
4. ACCELERATION TEST
1) Set vehicle speed at a speed greater that 40
km/h (25 MPH).
2) Ensure that vehicle continues to accelerate
while holding command switch in “RESUME/
ACCEL” mode, and that vehicle maintains that
optional speed when command switch is released.
5. DECELERATION TEST
1) Set vehicle speed at an optional speed greater
than 40 km/h (25 MPH).
2) Ensure that vehicle continues to decelerate
while holding command switch in “SET/COAST”
mode, and that it maintains that optional speed
when command switch is released.
NOTE:
When vehicle speed reaches the lower speed limit
of 30 km/h (19 MPH) during deceleration, cruise
control will be released.
2
DIAGNOSTICS [T2C1] 6-2
2. Pre-inspection
B: CRUISE CONTROL CABLE 2B4 : CHECK CABLE FREE PLAY.
2B1 : CHECK CRUISE CONTROL CABLE.

Ensure that throttle cam-to-lever clearance is
within specifications.
Check cruise control cable installation.
B6M0241A
S6M0099A
: Is throttle cam-to-lever clearance

: Is the cruise control cable securely
between 0 and 1 mm (0 and 0.04 in)?
installed to the left of the accelerator
cable? : Go to step 2C1.
: Go to step 2B2. : Adjust cable end by adjusting nuts. Go
: Install cruise control cable securely. Go to step 2C1.
to step 2B2. NOTE:
Ensure that cap is positioned in groove.
2B2 : CHECK ACCELERATOR CABLE. C: VACUUM HOSE
Check function of accelerator cable. 2C1 : CHECK VACUUM HOSE VISUALLY.
Check vacuum hose (which connects actuator and

intake manifold).
S6M0099A
: Does the accelerator cable throttle

cam move when the cruise control
S6M0101A
throttle is moved by hand?
: Repair accelerator cable throttle cam.
: Is there disconnection or cracks in
Go to step 2B3.
vacuum hose?
: Go to step 2B3.
: Replace vacuum hose. Go to step 2D1.
: Go to step 2D1.
2B3 : CHECK THROTTLE CAM.
Check function of throttle cam.

: Does the throttle cam move
smoothly?
: Go to step 2B4.
: Repair throttle cam. Go to step 2B4.
3
2. Pre-inspection
D: ACTUATOR 2D2 : MEASURE RESISTANCE OF VALVE.
2D1 : CHECK FUNCTION OF ACTUATOR.

1) Disconnect connector from actuator.
2) Measure resistance between terminals of
1) Disconnect vacuum hose from actuator. actuator.
Terminals
No. 2 — No. 3:
S6M0102A
2) Connect vacuum pump as shown in figure.

S6M0104

: Go to step 2D3.
: Replace actuator. <Ref. to 6-2
[W11B1].>
2D3 : MEASURE RESISTANCE OF VALVE.
S6M0103 Measure resistance between terminals of actuator.

3) Make sure that cruise control cable moves Terminals
smoothly and quickly when a vacuum pressure of No. 2 — No. 1:
40.0 kPa (300 mmHg, 11.81 inHg) is applied to
actuator.
: Does cruise control cable have a
stroke of 35 mm (1.38 in)?
: Go to step 2D2.
[W11B1].> Go to step 2D2.
NOTE:
I When vacuum pressure is released from condi-
S6M0104
tion 3) above, make sure the cable returns to its
original position smoothly and quickly.
I After inspection, disconnect vacuum pump and : Is resistance less than 69 Ω?
connect vacuum hose. : Go to step 2D4.
[W11B1].>
4
2. Pre-inspection
2D4 : MEASURE RESISTANCE OF VALVE. 2D6 : CHECK FOR LEAKAGE AND STICK-
ING OF VALVES.
Measure resistance between terminals of actuator.
When the battery cable is disconnected from
Terminals
former condition <Ref. to 6-2 [T2D5].> Step 2),
No. 2 — No. 4:
make sure the cable returns to its original position
smoothly.
: Does cruise control cable get back to
its original position within 1.5 sec-
onds?
: Go to step 2D7.
S6M0104 2D7 : CHECK CABLE MOVEMENT.
: Is resistance less than 69 Ω? Connect + (positive) battery cable to terminal No.

: Go to step 2D5. 2 and − (negative) battery cable to terminals No. 1,
: Replace actuator. <Ref. to 6-2 3 and 4 of actuator connector.
[W11B1].>
2D5 : CHECK FOR LEAKAGE AND STICK-

ING OF VALVES.
1) Disconnect connector from actuator.

2) Make sure that cruise control cable moves
smoothly when connecting + (positive) battery
cable to terminal No. 2 and − (negative) battery
cable to terminals No. 1, 3 and 4 of actuator con- S6M0105
nector.
: Does cruise control perform pull
operation?
: Go to step 2D8.
S6M0105
: Does cruise control cable have a

stroke of 35 mm (1.38 in) within 3 sec-
onds?
: Go to step 2D6.
5
2. Pre-inspection
2D8 : CHECK CABLE MOVEMENT. E: POWER SUPPLY

2E1 : CHECK BATTERY.
Connect + (positive) battery cable to terminal No.
2 and − (negative) battery cable to terminals No. 1
and 4 of actuator connector. Measure battery specific gravity of electrolyte.
: Is battery specific gravity more than
1.250?
: Go to step 2E2.
: Charge or replace battery. <Ref. to 6-2
[W2A0].> Go to step 2E2.
2E2 : CHECK FUSES, CONNECTORS AND

HARNESSES.
S6M0105
Check the condition of the main and other fuses,
: Does cruise control perform hold and harnesses and connectors. Also check for
operation? proper grounding.
: Go to step 2D9. : Is there anything unusual about the
: Replace actuator. <Ref. to 6-2 appearance of main fuse, fuse,
[W11B1].> Go to step 2D9. harness, connector and grounding?
: Repair or replace faulty parts. End of
2D9 : CHECK CABLE MOVEMENT. pre-inspection.
: End of pre-inspection.
Connect + (positive) battery cable to terminal No.
2 and − (negative) battery cable to terminal No. 4
of actuator connector.
S6M0105
: Does cruise control perform release

operation?
: Go to step 2E1.
[W11B1].> Go to step 2E1.
6
S6M0106A
(1) Actuator (with valves) (4) Cruise control command switch (7) Clutch switch (MT)
(2) Inhibitor switch (AT) (5) Cruise control module
(3) Cruise control main switch (6) Stop and brake switch
7
4. Schematic
4. Schematic
S6M0325
8
4. Schematic
MEMO:
9
5. Control Module I/O Signal
G6M0015
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Vent valve 1 I Power supply is ON when vehicle is stopped.
I ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
cruise control is operating.
Safety valve 2 I Power supply is ON when vehicle is stopped.
Ignition switch 3 I Battery voltage is present when ignition switch is turned ON.
I “0” volt is present when ignition switch is turned OFF.
Cruise control main switch 4 I Battery voltage is present when main power is turned ON.
I “0” volt is present when main power is turned OFF.
Power supply to vacuum valve, 5 I Battery voltage is present when main power is turned ON.
vent valve, safety valve and I “0” volt is present when main power is turned OFF.
indicator light
SET/COAST switch 6 I Battery voltage is present when command switch is turned to SET/COAST
position.
I “0” volt is present when command switch is released.
RESUME/ACCEL switch 7 I Battery voltage is present when command switch is turned to RESUME/
ACCEL position.
I “0” volt is present when command switch is released.
Brake switch 8 Set selector lever to any position other than “P” or “N” position (AT) / leave
clutch pedal released (MT), while cruise control main switch is turned ON.
Then check that;
I Battery voltage is present when brake pedal is released.
I “0” volt is present when brake pedal is depressed, or
I Battery voltage is present when clutch pedal is released (MT).
I “0” volt is present when clutch pedal is depressed (MT).
I Battery voltage is present when selector lever is in any position other than
“P” or “N” position (AT).
I “0” volt is present when selector lever is set to “P” or “N” position (AT).
Clutch switch (MT)/ 9 I Battery voltage is present when clutch pedal is released (MT).
Inhibitor switch (AT) I “0” volt is present when clutch pedal is depressed (MT).
I Battery voltage is present when selector lever is in any position other than
“P” or “N” position (AT).
I “0” volt is present when selector lever is set to “P” or “N” position (AT).
Vacuum valve 11 I Power supply is ON when vehicle is stopped.
Set signal to transmission con- 12 I TCM emits a ground-level signal while driving vehicle at least 40 km/h (25
trol module (AT) MPH) with SET switch ON.
Ground 13 —
Check connector/ 14 —
OBD-II service connector
Check connector/ 15 —
OBD-II service connector
10
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Vehicle speed sensor 2 (MT) 18 Lift-up the vehicle until all four wheels are raised off ground, and then rotate
Automatic transmission control any wheel manually. Approx. 5 and 0 volt pulse signals are alternately input to
module (AT) cruise control module.
Stop light switch 19 Turn ignition switch to OFF. Then check that;
I Battery voltage is present when brake pedal is depressed.
I “0” volt is present when brake pedal is released.
Ground 20 —
NOTE:
Voltage at terminals 1, 2, 11 and 12 cannot be checked unless vehicle is driving by cruise control operation.
11
6. Diagnostics Chart for On-board Diagnosis System
6. Diagnostics Chart for On- 6A5 : CHECK RESUME/ACCEL SWITCH.

board Diagnosis System
: Does RESUME/ACCEL switch func-
A: BASIC DIAGNOSTIC tion properly?
PROCEDURE : Go to step 6A6.
: Go to “Diagnostics Chart with Trouble
6A1 : CHECK CRUISE CONTROL MAIN Code”. <Ref. to 6-2 [T800].>
SWITCH.
6A6 : CHECK SET/COAST SWITCH.

1) Trouble occurs.
2) Perform pre-inspection. <Ref. to 6-2 [T200].>
3) Check cruise control main switch. : Does SET/COAST switch function
properly?
: Does cruise control main switch turn
: Go to step 6A7.
ON?
: Go to “Diagnostics Chart with Trouble
: Go to step 6A2. Code”. <Ref. to 6-2 [T800].>
: Go to “Diagnostics Chart for Power
Line”. <Ref. to 6-2 [T700].>
6A7 : CHECK CANCEL SWITCH.
6A2 : CHECK CRUISE SPEED IS SET. : Does CANCEL switch function prop-
erly?
: Does cruise speed properly set while : Go to step 6A8.
driving at minimum of 40 km/h (25 : Go to “Diagnostics Chart with Trouble
MPH)? Code”. <Ref. to 6-2 [T800].>
: Go to step 6A3.
: Go to “Diagnostics Chart with Trouble 6A8 : CHECK CRUISE SPEED IS
Code”. <Ref. to 6-2 [T800].> RELEASED.
6A3 : CHECK CRUISE CONTROL IS : Does cruise speed release when

RELEASED. brake pedal is depressed?
: Go to step 6A9.
: Does cruise control properly release : Go to “Diagnostics Chart with Trouble
during operation? Code”. <Ref. to 6-2 [T800].>
: Go to step 6A4.
: Go to “Diagnostics Chart with Trouble 6A9 : CHECK CRUISE SPEED IS
Code”. <Ref. to 6-2 [T800].> RELEASED.
6A4 : CHECK CRUISE SPEED IS HELD : Does cruise speed release when
WITHIN SET SPEED. clutch pedal is depressed?
: Cruise control system is in correct order.
: Does cruise speed hold within set : Go to “Diagnostics Chart with Trouble
speed ±3 km/h (2 MPH)? Code”. <Ref. to 6-2 [T800].>
: Go to step 6A5.
: Go to pre-inspection of actuator. <Ref.
to 6-2 [T2D0].>
12
6. Diagnostics Chart for On-board Diagnosis System
B: ON-BOARD DIAGNOSIS WITH 4) Drive vehicle at least 40 km/h (25 MPH) with
cruise speed set.
SELECT MONITOR 5) If cruise speed is canceled itself (without doing
1. GENERAL any cancel operations), a diagnostic code will
appear on select monitor display.
The on-board diagnosis function of the cruise con-
trol system uses an external select monitor. CAUTION:
The on-board diagnosis function operates in two I A diagnostic code will also appear when
categories, which are used depending on the type cruise cancel is effected by driver. Do not con-
of problems; fuse.
I Have a co-worker ride in vehicle to assist in
NOTE: diagnosis during driving.
Select monitor cartridge:
No. 24082AA130 NOTE:
Diagnostic code will be cleared by turning ignition
1) Cruise cancel conditions diagnosis switch or cruise control main switch to OFF.
(1) This category of diagnosis requires actual
vehicle driving in order to determine the cause,
3. REAL-TIME DIAGNOSIS
(as when cruise speed is cancelled during driv- 1) Connect select monitor.
ing although cruise cancel condition is not 2) Turn ignition switch and cruise control main
entered). switch to ON.
(2) Cruise control module memory stores the 3) Select the “Current Data Display & Save” mode
cancel condition (Code No.) which occurred on the select monitor “Cruise Control Diagnosis”
during driving. When there are plural cancel screen.
conditions (Code No.), they are shown on the 4) Ensure that normal indication is displayed when
select monitor. controls are operated as indicated below:
I Depress/release the brake pedal. (Stop light
CAUTION: switch and brake switch turn ON.)
I The cruise control memory stores not only I Turn ON the “SET/COAST” switch.
the cruise “cancel” which occurred (although I Turn ON the “RESUME/ACCEL” switch.
“cancel” operation is not entered by the I Depress/release the clutch pedal. (MT)
driver), but also the “cancel” condition input by I Set the selector lever to P or N. (AT)
the driver.
I The content of memory is cleared when igni-
tion switch or cruise main switch is turned OFF.
2) Real-time diagnosis
The real-time diagnosis function is used to deter-
mine whether or not the input signal system is in
good order, according to signal emitted from
switches, sensors, etc.
(1) Vehicle cannot be driven at cruise speed
because problems occurs in the cruise control
system or its associated circuits.
(2) Monitor the signal conditions from switches
and sensors.
2. CRUISE CANCEL CONDITIONS
DIAGNOSIS
1) Connect select monitor.
2) Start the engine and turn cruise control main
switch to ON.
3) Set select monitor in “All System Diagnosis”
mode.
NOTE:
The diagnostic code is also shown in the “Each
System Check” mode. This mode is called up on
the “Cruise Control Diagnosis” screen by selecting
the item “Cancel Code(s) Display”.
13
7. Diagnostics Chart for Power Line
7. Diagnostics Chart for Power

Line
A: BASIC DIAGNOSTICS
PROCEDURE
7A1 : DRIVE AT CRUISE SPEED.
: Can cruise speed be set?

: Go to “CHECK INDICATOR AND CIR-
CUIT IN CRUISE CONTROL MAIN
SWITCH”. <Ref. to 6-2 [T7B0].>
: Go to “CHECK CRUISE CONTROL
MAIN SWITCH”. <Ref. to 6-2 [T7C0].>
B: CHECK INDICATOR AND CIRCUIT IN CRUISE CONTROL MAIN SWITCH
DIAGNOSIS:
I Bulb failure or open harness of the indicator circuit in the cruise control main switch.
TROUBLE SYMPTOM:
I Cruise control can be set, normally indicator does not come on. (When main switch is pressed.)
WIRING DIAGRAM:
S6M0108
14
7B1 : CHECK CRUISE CONTROL MAIN 7B3 : CHECK CIRCUIT BETWEEN CRUISE
SWITCH. CONTROL MODULE AND CRUISE
CONTROL MAIN SWITCH INDICATOR
LIGHT.
1) Remove cruise control main switch.
2) Measure resistance between cruise control
main switch terminals. 1) Turn the ignition switch and cruise control main
switch to OFF.
Terminals 2) Remove the connector from the cruise control
No. 1 — No. 6: main switch.
3) Measure resistance of ground circuit between
the cruise control main switch connector and chas-
sis ground.
S6M0109A
: Is resistance between 10 and 80 Ω?

: Go to step 7B2.
: Replace switch illumination bulb. <Ref.
to 6-2 [W11B2].> B6M0531B

7B2 : CHECK CIRCUIT BETWEEN CRUISE
CONTROL MODULE AND CRUISE : Replace cruise control module. <Ref. to
CONTROL MAIN SWITCH INDICATOR 6-2 [W11B4].>
LIGHT. : Repair or replace wiring harness.
1) Turn the ignition switch to ON.

2) Turn cruise control main switch to ON.
3) Measure voltage between cruise control main
switch connector and the chassis ground.
B6M0528B

: Go to step 7B3.
: Repair or replace wiring harness.
15
C: CHECK CRUISE CONTROL MAIN SWITCH

DIAGNOSIS:
I Faulty cruise control main switch, or open harness.
TROUBLE SYMPTOM:
I Cruise control main switch is not turned ON and cruise control cannot be set.
NOTE:
When the main relay (built-in cruise control module) operates, the main switch circuit is in normal condi-
tion.
The main relay operation can be checked by hearing the operation sounds.
This operation sounds will be heard when ignition switch and cruise control main switch is turned to ON.
WIRING DIAGRAM:
S6M0108
16
7C1 : CHECK FUSE. 7C3 : CHECK CRUISE CONTROL MAIN

SWITCH.
Check fuse No. 18.
1) Turn ignition switch to OFF.
2) Remove cruise control main switch and discon-
nect connector.
4) Measure voltage between cruise control main
switch connector and chassis ground.
S6M0110A

: Replace fuse No. 18. Go to step 7C2.
: Go to step 7C2.
7C2 : CHECK POWER SUPPLY.

B6M0183C
2) Measure voltage between fuse & relay box con- : Is voltage more than 10 V?
nector and chassis ground. : Go to step 7C4.
Connector & terminal : Replace cruise control main switch.
(B152) No. 5 (+) — Chassis ground (−): <Ref. to 6-2 [W11B2].>
: Go to step 7C3. 7C4 : CHECK CRUISE CONTROL MAIN
: Replace fuse No. 18. When fuse No. 18 SWITCH.
is blown again, repair shorted parts of
circuit. Measure resistance between cruise control main
switch terminals.
Terminals
No. 3 — No. 5:
G6M0244
: Is resistance less than 10 Ω? (When

switch is ON.)
: Go to step 7C5.
: Replace cruise control main switch.
<Ref. to 6-2 [W11B2].>
17
7C5 : CHECK CRUISE CONTROL MAIN 7C7 : CHECK HARNESS BETWEEN

SWITCH. CRUISE CONTROL MAIN SWITCH
CONNECTOR AND CHASSIS
GROUND.
Measure resistance between cruise control main
switch terminals.
Measure voltage between terminal of cruise con-
Terminals trol main switch chassis ground.
No. 3 — No. 5:
G6M0244
: Is resistance less than 1 MΩ? (When S6M0111A
switch is OFF.)
: Go to step 7C6.
: Go to step 7C8.
: Replace cruise control main switch.
<Ref. to 6-2 [W11B2].>
7C8 : CHECK HARNESS BETWEEN

7C6 : CHECK HARNESS BETWEEN CRUISE CONTROL MODULE CON-
CRUISE CONTROL MAIN SWITCH NECTOR AND CHASSIS GROUND.
CONNECTOR AND CHASSIS
GROUND.
Measure voltage between terminal of cruise con-
trol module and chassis ground.
1) Connect connector.
2) Turn ignition switch to ON. Connector & terminal
3) Turn cruise control main switch to ON. (B94) No. 4 (+) — Chassis ground (−):
4) Measure voltage between terminal of cruise
control main switch and chassis ground.
S6M0111A

: Replace cruise control module. <Ref. to
6-2 [W11B4].>
S6M0111A
: Is voltage more than 10 V? NOTE:
: Go to step 7C7. Depress cruise control main switch with fingers
while measuring voltage between (B161) No. 5
: Repair or replace wiring harness. and chassis ground.
18
DIAGNOSTICS [T8A0] 6-2
8. Diagnostics Chart with Diagnostic Code

A: DIAGNOSTIC CODE LIST
Diagnostic
Item Contents of diagnosis Index No.
code
11 BRAKE SW/STOP SW Input signals from brake switch “OFF”, stop light <Ref. to 6-2 [T8B0].>
switch “ON”
(Brake pedal is depressed.)
12 CLUTCH SW/INHIBITOR SW Input signals from clutch switch “OFF” (MT), or <Ref. to 6-2 [T8C0].>
inhibitor switch “P or N” (AT)
[Clutch pedal is depressed (MT), or selector lever
is set to P or N position (AT).]
13 LOW SPEED LIMIT Low-speed control limiter <Ref. to 6-2 [T8D0].>
14 CANCEL SW Input signal from cancel switch <Ref. to 6-2 [T8E0].>
(faulty SET/COAST switch or RESUME/ACCEL
switch)
21 VACUUM VALVE Faulty vacuum valve or valve drive system <Ref. to 6-2 [T8F0].>
22 VENT 2 VALVE Faulty vent 2 valve or valve drive system <Ref. to 6-2 [T8F0].>
23 VENT 1 VALVE Faulty vent 1 valve or valve drive system <Ref. to 6-2 [T8F0].>
24 SPEED SENSOR Faulty vehicle speed sensor 2 (MT) or transmission <Ref. to 6-2 [T8D0].>
control module (AT)
25 CONTROL MODULE Faulty CPU RAM included in cruise control module <Ref. to 6-2 [T8G0].>
19
B: DIAGNOSTIC CODE 11 (BRAKE SWITCH, STOP LIGHT SWITCH)

DIAGNOSIS:
I Failure or disconnection of the stop light switch and brake switch.
TROUBLE SYMPTOM:
I Cruise control cannot be set.
WIRING DIAGRAM:
S6M0112
20
8B1 : CHECK BRAKE SWITCH. 8B2 : CHECK BRAKE SWITCH.
1) Turn ignition switch to ON. Check circuit between brake switch terminal.
2) Turn cruise control main switch to ON. Terminals
3) Apply parking brake securely. No. 1 — No. 4: (Brake switch)
4) Set select monitor in “Current Data Display &
Save” mode.
5) Depress the brake pedal and check signals for
proper operation.
(1) The Stop Lamp Switch shown on the dis-
play turns from “OFF” to “ON”.
(2) The Brake Switch shown on the display
turns from “OFF” to “ON”.
6) Release the brake pedal.
7) Remove connector of stop and brake switch.
8) Check circuit between brake switch terminal. G6M0183
Terminals
No. 1 — No. 4: (Brake switch) : Is resistance more than 1 MΩ? (When
brake pedal is depressed.)
: Go to step 8B3.
: Replace brake and stop light switch.
<Ref. to 4-5 [C1A0].>
8B3 : CHECK STOP LIGHT SWITCH.
Check circuit between stop light switch terminal.

G6M0183
Terminals
No. 2 — No. 3: (Stop light switch)
brake pedal is released.)
: Go to step 8B2.
<Ref. to 4-5 [C1A0].>
G6M0183
: Is resistance more than 1 MΩ? (When

brake pedal is released.)
: Go to step 8B4.
<Ref. to 4-5 [C1A0].>
21
8B4 : CHECK STOP LIGHT SWITCH.
Check circuit between stop light switch terminal.

Terminals
No. 2 — No. 3: (Stop light switch)
G6M0183

brake pedal is depressed.)
6-2 [W11B4].>
<Ref. to 4-5 [C1A0].>
22
MEMO:
23
C: DIAGNOSTIC CODE 12 (CLUTCH SWITCH, INHIBITOR SWITCH)

DIAGNOSIS:
I Failure or disconnection of the clutch switch. (MT)
I Failure or disconnection of the inhibitor switch. (AT)
TROUBLE SYMPTOM:
I Cruise control cannot be set.
WIRING DIAGRAM:
S6M0384
24
8C1 : CHECK CLUTCH SWITCH. (MT) 8C2 : CHECK CLUTCH SWITCH. (MT)
1) Turn ignition switch to ON. Check continuity of the clutch switch.

3) Apply parking brake securely. No. 1 — No. 2:
Save” mode.
5) Depress the clutch pedal and check signal for
proper operation. (MT)
The Clutch/Inhibitor Switch shown on the display
turns from “ON” to “OFF”.
6) Disconnect connector of clutch switch.
7) Check continuity of the clutch switch.
Terminals
No. 1 — No. 2:
G6M0184

clutch pedal is depressed.)
6-2 [W11B4].>
: Replace clutch switch. <Ref. to 4-5
[C1A0].>
G6M0184

clutch pedal is released.)
: Go to step 8C2.
: Replace clutch switch. <Ref. to 4-5
[C1A0].>
25
8C3 : CHECK INHIBITOR SWITCH. (AT) 8C4 : CHECK INHIBITOR SWITCH. (AT)
1) Turn ignition switch to ON. Check continuity of the inhibitor switch.

3) Apply parking brake securely. No. 7 — No. 12:
Save” mode.
5) Set the selector lever from P or N position to D
position and check signal for proper operation. (AT)
The Clutch/Inhibitor Switch shown on the display
turns from “ON” to “OFF”.
6) Set the selector lever to P or N position.
7) Disconnect connector of inhibitor switch.
8) Check continuity of the inhibitor switch.
Terminals
No. 7 — No. 12: B6M1426

selector lever is not in P or N.)
6-2 [W11B4].>
: Replace inhibitor switch. <Ref. to 3-2
[W2C0].> Repair inhibitor switch wiring
harness.
B6M1426

selector lever is in P or N.)
: Go to step 8C4.
: Replace inhibitor switch. <Ref. to 3-2
[W2C0].> Repair inhibitor switch wiring
harness.
26
MEMO:
27
D: DIAGNOSTIC CODE 13 AND 24 (SPEED SENSOR SYSTEM )

DIAGNOSIS:
I Disconnection or short circuit of vehicle speed sensor 2 (MT model) or transmission control module (AT
model).
TROUBLE SYMPTOM:
I Cruise control cannot be set. (Cancelled immediately.)
WIRING DIAGRAM:
H6M0775
28
8D1 : CHECK TRANSMISSION TYPE. 8D3 : CHECK HARNESS CONNECTOR

BETWEEN BATTERY AND VEHICLE
SPEED SENSOR 2.
: Is the transmission type MT?
: Go to step 8D2.
: Go to step 8D6.
2) Measure voltage between vehicle speed sensor
2 connector (B17) and chassis ground.
8D2 : CHECK HARNESS CONNECTOR
BETWEEN CRUISE CONTROL MOD-
ULE AND VEHICLE SPEED SENSOR
2.
1) Disconnect connector from vehicle speed sen-

sor 2 and cruise control module.
2) Measure resistance of harness connector
between vehicle speed sensor 2 and cruise control
module.
(B17) No. 1 — (B94) No. 18:
B6M0945A

: Go to step 8D4.
: Repair harness connector between bat-
tery and vehicle speed sensor 2.
8D4 : CHECK HARNESS CONNECTOR

BETWEEN VEHICLE SPEED SENSOR
S6M0327A
2 AND ENGINE GROUND.
: Is the resistance less than 10 Ω? 1) Turn ignition switch to OFF.

: Go to step 8D3. 2) Measure resistance between vehicle speed
sensor 2 connector (B17) and engine ground.
: Repair wiring harness.
(B17) No. 2 (+) — Engine ground (−):
B6M0946A

: Go to step 8D5.
vehicle speed sensor 2 and engine
ground.
29
8D5 : CHECK VEHICLE SPEED SENSOR 2. 8D6 : CHECK HARNESS CONNECTOR

BETWEEN CRUISE CONTROL MOD-
ULE AND AUTOMATIC TRANSMIS-
1) Connect connector to vehicle speed sensor 2.
SION CONTROL MODULE.
1) Disconnect connector from automatic transmis-
WARNING:
sion control module and cruise control module.
Be careful not to be caught up by the running
2) Measure resistance between cruise control
wheels.
module connector and automatic transmission
3) Set oscilloscope to vehicle speed sensor 2 con- control module connector.
nector terminals.
CAUTION:
Positive probe; (B17) No. 1
Earth lead; (B17) No. 2
5 mm (0.20 in).
(B94) No. 18 — (B55) No. 13:
H6M0789A
4) Drive the vehicle at speed greater than 20 km/h

(12 MPH).
5) Measure signal voltage indicated on oscillo-
scope. S6M0328A

: Go to step 8D7.
cruise control module and automatic
transmission control module.
H6M0790A

6-2 [W11B4].>
: Replace vehicle speed sensor 2.
30
8D7 : CHECK AUTOMATIC TRANSMISSION

CONTROL MODULE.
1) Connect connector to automatic transmission

control module.
WARNING:
Be careful not to be caught by the running
wheels.
3) Drive the vehicle faster than 10 km/h (6 MPH).
4) Measure voltage between automatic transmis-
sion control module connector (B55) and chassis
ground.
CAUTION:
5 mm (0.20 in).
B6M0949A
: Is the voltage less than 1 V ←→ more

than 4 V?
6-2 [W11B4].>
: Replace automatic transmission control
module. <Ref. to 3-2 [W22A0].>
31
E: DIAGNOSTIC CODE 14 (SET/COAST SWITCH, RESUME/ACCEL SWITCH,

CANCEL SWITCH)
DIAGNOSIS:
I Short circuit inside the SET SW and RESUME SW.
TROUBLE SYMPTOM:
I Cruise control cannot be set. (Cancelled immediately.)
WIRING DIAGRAM:
S6M0123
32
DIAGNOSTICS [T8E3] 6-2
8E1 : CHECK POWER SUPPLY. 8E2 : CHECK CRUISE CONTROL COM-

MAND SWITCH.
2) Turn cruise control main switch to ON. 1) Turn ignition switch to OFF.
3) Set select monitor in “Current Data Display & 2) Connect connector of cruise control command
Save” mode. switch.
4) Check signals for proper operation. 3) Turn ignition switch to ON.
(1) When pushing the SET/COAST switch: 4) Measure voltage between cruise control com-
The SET/COAST switch shown on the display mand switch connector and chassis ground.
turns from “OFF” to “ON”. Terminals
(2) When pushing the RESUME/ACCEL No. 2 (+) — Chassis ground (−):
switch:
The RESUME/ACCEL switch shown on the dis-
play turns from “OFF” to “ON”.
5) Turn ignition switch to OFF.
6) Disconnect connector from cruise control com-
mand switch.
8) Measure voltage between cruise control com-
mand switch connector and chassis ground.
Terminals
No. 1 (+) — Chassis ground (−): S6M0124
: Is voltage more than 10 V? (When

SET/COAST switch is ON.)
: Go to step 8E3.
: Replace cruise control command
switch. <Ref. to 6-2 [W11B3].>
8E3 : CHECK CRUISE CONTROL COM-

MAND SWITCH.
S6M0124
Measure voltage between cruise control command

: Is voltage more than 10 V? switch connector and chassis ground.
: Go to step 8E2. Terminals
: Repair or replace wiring harness No. 3 (+) — Chassis ground (−):
between fuse & relay box and cruise
control command switch. <Ref. to 6-2
[W11B3].>
S6M0124

RESUME/ACCEL switch is ON.)
: Go to step 8E4.
33
8E4 : CHECK CRUISE CONTROL COM- 8E6 : CHECK CRUISE CONTROL COM-
MAND SWITCH. MAND SWITCH.
Measure voltage between cruise control command 1) Turn ignition switch to OFF.
switch connector and chassis ground. 2) Disconnect connector from cruise control com-
Terminals mand switch.
No. 2 (+) — Chassis ground (−): 3) Measure resistance between terminals of
cruise control command switch connector (switch
side) to check the switch operation.
Terminals
No. 1 — No. 2:
S6M0124

CANCEL switch is ON.)
S6M0125
: Go to step 8E5.
SET/COAST switch is ON.)
: Go to step 8E7.
8E5 : CHECK CRUISE CONTROL COM-
MAND SWITCH. : Replace cruise control command
Measure voltage between cruise control command
switch connector and chassis ground.
Terminals
No. 3 (+) — Chassis ground (−):
S6M0124

CANCEL switch is ON.)
: Go to step 8E6.
34
8E7 : CHECK CRUISE CONTROL COM- 8E9 : CHECK CRUISE CONTROL COM-
MAND SWITCH. MAND SWITCH.
Measure resistance between terminals of cruise Measure resistance between terminals of cruise
control command switch connector (switch side) to control command switch connector (switch side) to
check the switch operation. check the switch operation.
Terminals Terminals
No. 1 — No. 2: No. 1 — No. 3:
S6M0125 S6M0125
: Is resistance more than 1 MΩ? (When : Is resistance more than 1 MΩ? (When
SET/COAST switch is OFF.) RESUME/ACCEL switch is OFF.)
: Go to step 8E8. : Go to step 8E10.
: Replace cruise control command : Replace cruise control command
switch. <Ref. to 6-2 [W11B3].> switch. <Ref. to 6-2 [W11B3].>
8E8 : CHECK CRUISE CONTROL COM- 8E10 : CHECK HARNESS CONNECTOR

MAND SWITCH. BETWEEN CRUISE CONTROL COM-
MAND SWITCH AND CRUISE CON-
Measure resistance between terminals of cruise TROL MODULE.
control command switch connector (switch side) to
check the switch operation. 1) Disconnect connector from cruise control mod-
ule.
Terminals
2) Measure resistance of harness connector
No. 1 — No. 3:
between cruise control command switch and
cruise control module.
No. 2 (command switch) — (B94) No. 6:
S6M0125

RESUME/ACCEL switch is ON.)
S6M0126A
: Go to step 8E9.
: Replace cruise control command : Is resistance less than 10 Ω?
switch. <Ref. to 6-2 [W11B3].> : Go to step 8E11.
35
8E11 : CHECK HARNESS CONNECTOR

BETWEEN CRUISE CONTROL COM-
MAND SWITCH AND CRUISE CON-
TROL MODULE.
Measure resistance of harness connector between

cruise control command switch and cruise control
module.
No. 3 (command switch) — (B94) No. 7:
S6M0127A

6-2 [W11B4].>
36
MEMO:
37
6-2 [T8F0] DIAGNOSTICS
F: DIAGNOSTIC CODE 21, 22 AND 23 (VACUUM VALVE, VENT 2 VALVE,

VENT 1 VALVE)
DIAGNOSIS:
I Open or poor contact of vacuum valve, vent 2 valve and vent 1 valve.
TROUBLE SYMPTOM:
I Cruise control cannot be set. (Cancels immediately.)
WIRING DIAGRAM:
S6M0128
38
8F1 : MEASURE RESISTANCE OF VACUUM 8F3 : MEASURE RESISTANCE OF VACUUM

VALVE, VENT 2 VALVE AND VENT 1 VALVE, VENT 2 VALVE AND VENT 1
VALVE. VALVE.
1) Disconnect connector from actuator. Measure resistance of vacuum valve, vent 2 valve
2) Measure resistance of vacuum valve, vent 2 and vent 1 valve.
valve and vent 1 valve. Terminals
Terminals No. 2 — No. 4:
No. 2 — No. 3:
S6M0104
S6M0104
: Is resistance less than 22 Ω? : Go to step 8F4.
: Go to step 8F2. : Replace actuator. <Ref. to 6-2
: Replace actuator. <Ref. to 6-2 [W11B1].>
[W11B1].>
8F2 : MEASURE RESISTANCE OF VACUUM

VALVE, VENT 2 VALVE AND VENT 1
VALVE.
Measure resistance of vacuum valve, vent 2 valve

and vent 1 valve.
Terminals
No. 2 — No. 1:
S6M0104

: Go to step 8F3.
[W11B1].>
39
6-2 [T8F4] DIAGNOSTICS
8F4 : PERFORM A CIRCUIT TEST IN HAR- 8F5 : PERFORM A CIRCUIT TEST IN HAR-
NESS BETWEEN ACTUATOR NESS BETWEEN ACTUATOR
(VACUUM VALVE, VENT 2 VALVE (VACUUM VALVE, VENT 2 VALVE
AND VENT 1 VALVE) AND CRUISE AND VENT 1 VALVE) AND CRUISE
CONTROL MODULE. CONTROL MODULE.
1) Disconnect connector from cruise control mod- Measure resistance of harness connector between
ule. cruise control module, vacuum valve, vent 2 valve
2) Measure resistance of harness connector and vent 1 valve.
between cruise control module, vacuum valve, Connector & terminal
vent 2 valve and vent 1 valve. (B7) No. 2 — (B94) No. 8:
(B7) No. 1 — (B94) No. 1:
S6M0131A
S6M0130A : Is resistance less than 10 Ω?

: Go to step 8F6.
: Repair or replace wiring harness
: Go to step 8F5. between actuator <Ref. to 6-2
: Repair or replace wiring harness [W11B1].> and cruise control module
between actuator <Ref. to 6-2 <Ref. to 6-2 [W11B4].>.
[W11B1].> and cruise control module
<Ref. to 6-2 [W11B4].>.
40
8F6 : PERFORM A CIRCUIT TEST IN HAR- 8F7 : PERFORM A CIRCUIT TEST IN HAR-
NESS BETWEEN ACTUATOR NESS BETWEEN ACTUATOR
(VACUUM VALVE, VENT 2 VALVE (VACUUM VALVE, VENT 2 VALVE
AND VENT 1 VALVE) AND CRUISE AND VENT 1 VALVE) AND CRUISE
CONTROL MODULE. CONTROL MODULE.
Measure resistance of harness connector between Measure resistance of harness connector between
cruise control module, vacuum valve, vent 2 valve cruise control module, vacuum valve, vent 2 valve
and vent 1 valve. and vent 1 valve.
(B7) No. 3 — (B94) No. 11: (B7) No. 4 — (B94) No. 2:
S6M0133A
S6M0132A
: Is resistance less than 10 Ω? : Is resistance less than 10 Ω?

: Go to step 8F7. : Replace cruise control module.
between actuator <Ref. to 6-2
between actuator <Ref. to 6-2 [W11B1].> and cruise control module
[W11B1].> and cruise control module <Ref. to 6-2 [W11B4].>.
<Ref. to 6-2 [W11B4].>.
41
6-2 [T8G0] DIAGNOSTICS
9. Diagnostics Chart with Select Monitor
G: DIAGNOSTIC CODE 25 (CRUISE 9. Diagnostics Chart with

CONTROL MODULE BUILT-IN Select Monitor
RELAY, CPU RAM) A: FUNCTION MODE
DIAGNOSIS:
NOTE:
I Poor welding of built-in relay of cruise control Applicable select monitor cartridge:
module. No. 24082AA130
I Failure of built-in CPU RAM of cruise control
module. Select the “Cruise Control” system using the select
monitor and set the “Current Data Display & Save”
TROUBLE SYMPTOM:
mode. The following parameters will then appear
I Cruise control is canceled and memorized on the display.
cruise speed is also canceled. I Vehicle Speed
I Once cruise control is canceled, cruise control The current vehicle speed is shown on the display.
cannot be set until the ignition switch and cruise I Stop Lamp Switch
control main switch turns OFF, and then turns ON When the brake pedal is depressed, the stop lamp
again. switch shown on the display turns from “OFF” to
“ON”.
NOTE:
I Brake Switch
Check input/output signal and vehicle speed signal When the brake pedal is depressed, the brake
with select monitor. When signals are in good switch shown on the display turns from “OFF” to
condition, failure is in cruise control module. “ON”.
(Check power supply and ground conditions of I “SET/COAST” Switch
cruise control module.) When the cruise control command switch is placed
in the “SET/COAST” position, the SET/COAST
switch shown on the display turns from “OFF” to
“ON”.
I “RESUME/ACCEL” Switch
When the cruise control command switch is placed
in the “RESUME/ACCEL” position, the RESUME/
ACCEL switch shown on the display turns from
“OFF” to “ON”.
I Clutch/Inhibitor Switch
When the clutch pedal is depressed, the clutch/
inhibitor switch shown on the display turns from
“ON” to “OFF”. (MT models)
When the selector lever is moved from the “N” or
“P” position to any other position, the clutch/
inhibitor switch shown on the display turns from
“ON” to “OFF”.
42

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5-1 [S1A0] SPECIFICATIONS AND SERVICE DATA

2. Body Datum Points

B: LUGGAGE COMPARTMENT AND ROOM

D: DATUM POINT LOCATION

3. Datum Dimensions NOTE:

C: DOORS AND REAR QUARTER

D: FRONT WINDSHIELD AND REAR WINDOW

E: TRUNK LID AND REAR GATE

4. Datum Points and Dimensions Concerning On-Board Aiming

1. Front Hood and Hood Lock

(1) Weatherstrip (10) Harness (19) Shutting ASSY (RH)

6. Steering Support Beam

(1) Bracket Tightening torque: N·m (kg-m, ft-lb)

(1) Guard pipe Tightening torque: N·m (kg-m, ft-lb)

1. Hood 2. HOOD LOCK

3) Detach front hood from hinges.

5) Installation is in the reverse order of removal.

B: POINTS TO CHECK 2. Trunk Lid

2) Remove the left and right torsion bars.

3. TRUNK LID LOCK ASSEMBLY AND 7) Disconnect cable from striker.

8) Installation is in the reverse order of removal.

4. TRUNK LID OPENER

3. Fuel Flap 4. Front Bumper

2) Installation is in the reverse order of removal.

2. FUEL FLAP OPENER

8) Remove bolts from lower side of bumper.

5) Detach fuel lock holder by turning it.

9) Remove bolts (engine compartment side) from 5. Rear Bumper

10) Remove turn signal light connector.

4) Remove bolts from bumper stay.

12) Installation is in the reverse order of removal.

6) Installation is in the reverse order of removal. 2. WAGON

6. Coating Method for PP Bumper

7. Repair Instructions for Colored PP Bumper

A: MINOR DAMAGE CAUSING ONLY A CHANGE IN THE LUSTRE OF THE

B: DEEP DAMAGE CAUSED BY SCRATCHING FENCES, ETC.

C: DEEP DAMAGE SUCH AS A BREAK OR HOLE THAT REQUIRES FILLING

Process Process name Job contents

Process Process name Job contents

Process Process name Job contents

8. Side Protector NOTE:

4) Installation is in the reverse order of removal.

9. Front Fender NOTE:

6) Remove body protector. (This step may be

10. Mud Guard and Rear Arch 11. Cowl Panel

2) Remove arch protectors.

12. Molding and Retainer 13. Front Grille

14. Sunroof 5) Close sunroof and remove nuts.

6) Remove sunroof panel.

4) Remove relay by pulling it out.

4) Disconnect connector between body harness B: INSTALLATION

5) Loosen two mounting bolts near motor. (Do not G5M0198

7) Remove sunroof frame.

4) Install sunroof panel.

5) Adjust height by turning adjusting nut. 8) Install drain tubes.

6) Tighten set bracket mounting bolts.

11) Install sunroof trim, pillar trim, rear quarter trim

15. Rear Spoiler 16. Hood Duct

2) Disconnect high-mount stop light connector.