Home

6 - Body - Ken Gilbert

1. 2 CHECK BATTERY DISCONNECT PROTECTION 1 Remove the key from the ignition switch If NG replace the security control module 2 Close all the doors and rear gate or trunk lid 3 Open the front hood 4 Press the LOCK ARM button of the transmitter 5 Disconnect the ground cable from the battery 6 Reconnect the cable to the battery 7 Check that the security indicator light blinks after reconnecting the battery cable SL 22 SECURITY SYSTEM SECURITY AND LOCKS 3 SYMPTOM CHART The security system cannot be set 1 Check the transmitter func lt Ref to SL 16 CHECK TRANS tion MITTER BATTERY AND FUNC TION INSPECTION Keyless Entry System gt 2 Check the fuse lt Ref to SL 24 CHECK FUSE INSPECTION Security System gt 3 Check the security control lt Ref to SL 24 CHECK POWER module power supply and SUPPLY AND GROUND CIRCUIT ground circuit INSPECTION Security System gt 4 Check the door switch Ref to 51 24 CHECK DOOR SWITCH INSPECTION Security System 5 Replace the security control Ref to SL 45 Security Control module Module Ref to SL 25 CHECK SECURITY INDICATOR LIGHT CIRCUIT INSPECTION Security System Ref to SL 27 CHECK CLEAR ANCE LIGHT OPERATION INSPECTION Security System Ref to SL 24 CHECK DOOR SWITCH INSPECTION Security System All functions Check the door switch Ref to SL 24 CHEC
2. Replace the body harness with front sub sensor har ness LH po Step eck CHECK FRONT SUB SENSOR HARNESS Isthe resistance less than 10 Go to step 8 LH Q 1 Connect the connector 2F in the test har ness F to the connector AB12 2 Measure the resistance between connector 3H in the test harness H and connector 3F in the test harness F Connector amp terminal 3F No 5 3H No 5 3F No 6 3H No 6 CHECK FRONT SUB SENSOR HARNESS Is the resistance more than 1M Go to step 9 Replace the body LH Q harness with front Measure the resistance between connector sub sensor har 3H in the test harness H and connector 3F ness LH in the test harness F Connector amp terminal 3F No 6 3H No 6 3F No 5 3H No 5 CHECK FRONT SUB SENSOR HARNESS Is the resistance more than 1 Go to step 10 Replace the body LH MQ harness with front Measure the resistance between connector sub sensor har in the test harness F and the chassis ness LH ground Connector amp terminal 3F No 5 Chassis ground 3F No 6 Chassis ground CHECK FRONT SUB SENSOR LH Is the resistance between Go to step 11 Replace the front 1 Connect connector 2H in the test harness 7500 and 1 KO sub sensor LH H to the front sub sensor LH Ref to AB 18 2 Measure the resistance of the connector Front Sub Sen 3H in the test harness H SOr Connector amp terminal 3H N
3. Cor Blus Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow AB 18 1 2 3 4 5 6 ELECTRICAL COMPONENTS LOCATION AIRBAG SYSTEM DIAGNOSTICS Drivers airbag module Roll connector Passengers airbag module Airbag contro module Side airbag module LH Side airbag module RH 7 8 9 10 11 12 Seat belt pretensioner LH Seat belt pretensioner RH Front sub sensor LH Front sub sensor RH Side airbag sensor LH Side airbag sensor RH AB 19 13 14 15 16 17 Airbag main harness Front sub sensor harness LH Front sub sensor harness RH Side airbag harness LH Side airbag harness RH A B CONTROL MODULE I O SIGNAL AIRBAG SYSTEM DIAGNOSTICS 5 A B Control Module I O Signal A SCHEMATIC lt Ref to WI 31 Airbag System gt AB 20 AIRBAG CONNECTOR 6 Airbag Connector A OPERATION 1 POWER SUPPLY 1 How to disconnect 1 Move the slide lock A in the direction of the arrow 2 Pull the female connector in the direction of the arrow with slide lock A moved CAUTION When pulling be sure to hold onto the connec tor and not the wire 2 How to connect Holding the connector A and push it in carefully until a connecting sound is heard A REO013 CAUTION Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is lock
4. Flashing code 21 OFF Flashing normal OFF code B5M0117A 4 Turn the ignition switch OFF and disconnect the diagnosis terminal from the diagnosis connector terminal No 1 5 Wind the tape around the diagnosis terminal and return it to its original position AB 24 INSPECTION MODE 9 Inspection Mode A OPERATION According to the contents of check list reproduce the condition which problem has occurred as much as possible AB 25 AIRBAG SYSTEM DIAGNOSTICS CLEAR MEMORY MODE AIRBAG SYSTEM DIAGNOSTICS 10 Clear Memory Mode A OPERATION 1 Turn the ignition switch ON 2 Connect the diagnosis terminal 1 to the diagno sis connector 2 terminal No 1 in the driver s seat lower cover area 3 While the warning light flashes connect another diagnosis terminal 3 to the diagnosis connector lerminal No 2 4 Once the memory is erased the warning light re turns to the normal flash rate 0 6 sec on The fail ure to recover the normal flash rate indicates that trouble parts still remain Having repaired such parts erase the memory again and confirm that the normal flash rate has returned 5 When the memory has been cleared disconnect the diagnosis terminal from the diagnosis connec tor 6 Wind the tape around the diagnosis terminal and return it to its original position AB 26 AIRBAG WARNING LIGHT FAILURE AIRBAG SYSTEM DIAGNOSTICS 11 Airbag Warning Ligh
5. Mortuo eo A epe tede I e PERDERE 19 18 Back up Eight BUID eoa tne to Cont c oisi do 20 19 Rear Turn Signal Light Bulb hn e RR good uva 21 20 Rear Side Marker Light Bulb Vues este TT 22 21 License Plate Ligat einn area eden 23 22 JHighsmo nted Stop Light eere ier viera s ben ei aidera d A V Rada 24 23 25 24 Room eh eundi dip A NES SIUS Reps MEINT TNR RERUMS 26 25 Luggage HOO oiii deir ipt Ud Du Ust teed 27 26 Trunk Room Light n tdem en el sod 28 27 GIOVE Hem s 29 FEET ON AT EE A I PETRA TI ma are SEES s GENERAL DESCRIPTION LIGHTING SYSTEM 1 General Description A SPECIFICATIONS Headlight Front turn signal light 12V 21W Side marker light Parking ight Front fog light 12 V 55 W Halogen TailStop light Taillight Stop light Turn signal light Back up light 12V 21W Sedan Rear combination light Tail Stop light 12 V 21 5 Turn signal light 12V 21W Wagon 9 9 Back up light 12V 21W Side marker light 12V 5W License plate light 12V 5W Sedan 12V 21W High top light Sedan igh mounted stop lig Wagon 12V 13W 12V 8W 12V 8W 12V 13
6. deseo duo suu dup Rr ap IM Es 3 3 Datum DImiensionS ooo edd entem Octa dese dt Lube RUPEE NE To qas 11 I aes 705 Pe TS GENERAL DESCRIPTION BODY STRUCTURE 1 General Description A PREPARATION TOOL TOOL NAME REMARKS Tram tracking gauge Used for measuring dimen sion sion BS 2 DATUM POINTS BODY STRUCTURE 2 Datum Points A LOCATION NOTE Datum points are specified for body repair e Guide holes locators and indents are provided to facilitate panel replacement and to increase alignment accuracy e Both right and left reference points are symmetrical 1 WAGON SEDAN 8 Radiator attaching hole 12 mm 0 47 in dia Symmetrical Fender attaching hole 7 mm 0 28 in dia Symmetrical Fender attaching hole 10 mm 0 39 in dia Symmetrical Hood hinge attaching hole 12 mm 0 47 in dia Symmetrical Radiator panel side gauge hole 20 mm 0 79 in dia Symmetrical Fender attaching hole 9 mm 0 35 in dia Symmetrical Gauge hole 12 mm 0 47 in dia Symmetrical Front suspension cross member attaching hole 12 4 mm 0 488 in dia Symmetrical 10 12 18 19 20 21 22 Cowl panel attaching hole 6 mm 0 24 in dia Vehicle center Front glass attaching hole Right 6 5 mm 0 256 in dia Left 6 5 x 10 mm 0 256 x 0 39 in dia Fender attaching hole 12 mm 0 47 in dia Symmetrical Fender attaching hole 12 mm
7. 12V 5W 12V 1 4W Room light Spot light Luggage room light Trunk room light Glove box light B PRECAUTIONS e After reassembly make sure functional parts op e Before disassembling or reassembling parts al erate smoothly ways disconnect the battery ground cable When WARNING replacing the radio control module and other parts e The air bag system wiring harness is routed provided with memory functions record the memo near electrical parts and switches All air bag ry contents before disconnecting the battery system wiring harnesses and connectors are ground cable Otherwise the memory will be yellow Do not use an electric test equipment erased on these circuits Heassemble in reverse order of disassembly un e Be careful not to damage the air bag system less otherwise indicated wiring harness when servicing electrical parts e Adjust parts to the given specifications and switches Connect the connectors and hoses securely dur ing reassembly C PREPARATION TOOL 1 GENERAL TOOLS TOOL NAME REMARKS Used for measuring resistance and voltage HEADLIGHT AND TAIL LIGHT SYSTEM LIGHTING SYSTEM 2 Headlight and Tall Light Sys 2 TAIL AND ILLUMINATION RELAY tem Measure the tail and illumination relay resistance between terminals when connecting terminal No 4 A SCHEMATIC to battery positive terminal and terminal No 3 to dt inal 1 HEADLIGHT battery ground ter
8. GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS TEST HARNESS F ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FC010 TEST HARNESS F Used when measuring voltage resistance of air bag module harnesses AB 10 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS TEST HARNESS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FC020 TEST HARNESS G Used when measuring voltage resistance of side airbag sensor RE0037 AB 11 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS e TEST HARNESS H ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FA030 TEST HARNESS Used when measuring voltage resistance of front sub sensor RE0039 AB 12 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS TEST HARNESS L ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FE000 TEST HARNESS L Used when measuring voltage resistance of seat belt pretensioner AB 13 GENERAL DESCRIPTION 0 z o lt a 2 TY H D gt 27 lt a o o 2 tr lt I F o LLI H N lt z H n E O m 2 2 z H z lt cr 2 2 Used when measuring voltage resistance of air bag control module TEST HARNESS 98299FC040 T E EB B e r NEO c e r o t Olt N T jaN Wij 100 Q
9. Hook pawl 4 Remove the screws of combination meter pull out the meter toward you 5 Disconnect the connector in the upper area of combination meter to remove the meter CAUTION Be careful to damage the meter or instru ment panel e Pay particular attention to avoid damaging the meter glass IDI 11 COMBINATION METER ASSEMBLY INSTRUMENTATION DRIVER INFO C DISASSEMBLY CAUTION Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces 1 Disengage claw F to remove case B from back cover A 2 Disengage claw G to remove meter glass E reflector D and window plate C from inner case BO0014 3 Pull up claw A in portion B of combination 1 BULB REPLACEMENT meter printed circuit C with combination pliers Push out speedometer and tachometer assembly D and fuel gauge and water temperature gauge assembly E using hole F 4 Pull up the claw in the center of combination meter printed circuit C and remove the combina tion meter printed circuit from case G 4 5 6 3 fei te 1 Tachometer 2 Speedometer and tachometer 3 Turn RH 4 Hl beam 5 Speedometer 6 Turn LH 7 Fuel gauge 8 Temperature gauge 9 LCD Outside temperature indicator 10 LCD Odometer and tripmeter D ASSEMBLY Assemble in the reverse order of disassembly IDI 12 ST pte sls c NTR ET TE TN
10. 3 Check motor clutch drive Ref to CC 36 37 ACTUATOR MOTOR CLUTCH system Diagnostics Chart with Diagnostic Trouble Code Ref to CC 18 CHECK CRUISE CONTROL COM MAND SWITCH Diagnostics Chart with Symptom 2 Check motor drive sys Ref to CC 34 DTC 35 AND 36 ACTUATOR MOTOR Cruise control is not released after CANCEL switch has been pressed 1 Check CANCEL switch o lt o et D 3 tem Diagnostics Chart with Diagnostic Trouble Code 3 Check motor clutch drive Ref to CC 36 DTC 37 ACTUATOR MOTOR CLUTCH system Diagnostics Chart with Diagnostic Trouble Code Cruise control is not released 1 Check stop light switch Ref to CC 20 CHECK STOP LIGHT SWITCH AND after brake pedal has been and brake switch BRAKE SWITCH Diagnostics Chart with Symptom depressed Ref to CC 34 DTC 35 AND 36 ACTUATOR MOTOR Diagnostics Chart with Diagnostic Trouble Code 3 Check motor clutch drive Ref to CC 36 DTC 37 ACTUATOR MOTOR CLUTCH Diagnostics Chart with Diagnostic Trouble Code 2 Check motor drive sys D 11 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS Cruise control is not released 1 Check clutch switch lt Ref to CC 22 CHECK CLUTCH SWITCH Diag after clutch pedal has been nostics Chart with Symptom gt depressed MT 2 Check motor drive sys lt Ref to CC 34 DTC 35 AND 3
11. 33 LH to 97 LH 20 to 65 77 RH to 91 LH GT RH to 31 LH 77 LH to 91 RH 2 820 togon __ BS 17 BODY STRUCTURE 6 SEDAN FRONT STRUCTURE DATUM DIMENSIONS Unit mm in Dimension Pompom Dimenin _ 0 to 71 RH 60 to 71 LH 51 60 0 62 RH 2 LH to 63 LP 66 LH HO 62 RH to 62 LH to 66 R BS 18 DATUM DIMENSIONS BODY STRUCTURE 7 SEDAN REAR STRUCTURE Unit mm in Paint to point Paint to pom 50 to 60 65 to 76 LH 1 544 60 79 1 581 62 24 68 RH to 68 LH 681 26 81 537 21 14 60 to 63 LH 69 to 76 LH 537 21 14 65 og6 RH 5 19 DATUM DIMENSIONS BODY STRUCTURE BS 20 BODY STRUCTURE BS 2 INSTRUMENTATION DRIVER INFO ee IV Page General DESCHOUOM b RE UR 2 Combination Meter System eec v eroe Ek e ELE E Eia 4 Combination Meter Assembly 11 Speedometer T 13 ACTON T EE DTI 14 FUS 15 Water Temperature Gauge 16 Almbient SENSO sueco esta 17 GENERAL DESCRIPTION IN
12. Is the voltage more than 10 V Go to step 2 is the voltage more than 10 V Go to step 3 Is the resistance less than 10 Q IDI 5 Replace the com bination meter printed circuit Check the harness for open or short between the igni tion switch and combination meter Check the harness for open or short between the fuse and combination meter Repair the wiring harness COMBINATION METER SYSTEM INSTRUMENTATION DRIVER INFO 3 CHECK VEHICLE SPEED SENSOR Check Yes Is the voltage less than 1V Check the speed lt more than 4 V ometer Ref to CHECK VEHICLE SPEED SENSOR 1 Set the vehicle on a free roller or lift up the Go to step 2 vehicle and support it with safety stands IDI 13 2 Remove the combination meter with harness REMOVAL connector Speedometer Warning Be careful not to get caught in the running wheels 3 Drive the vehicle at a speed greater than 20 km h 12 MPH 4 Measure the voltage between the combina tion meter connector i10 and chassis ground Connector amp terminal 110 No 2 Chassis ground CHECK VEHICLE SPEED SENSOR POWER Is the voltage more than 10 V Go to step 3 SUPPLY 1 Turn the ignition switch to OFF 2 Disconnect the vehicle speed sensor har ness connector 3 Turn the ignition switch to ON 4 Measure the voltage between the vehicle speed sensor connector B17 and engine ground Con
13. Does the LED blink one time Does the horn signal chirp The horn chirp function is OK Go to step 2 Check the trans mitter function lt Ref to SL 16 CHECK TRANS MITTER BAT TERY AND FUNCTION INSPECTION Keyless Entry Sys tem gt Does the horn signal chirp The horn chirp function is OK SL 16 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 4 CHECK FUSE CHECK FUSE Is the fuse blown 15 A Replace the fuse Check the power Remove and visually check the fuse No 2 in with a new one supply and ground the main fuse box circuit lt Ref to SL 17 CHECK POWER SUPPLY AND GROUND CIRCUIT Keyless Entry System gt 5 CHECK POWER SUPPLY AND GROUND CIRCUIT CHECK POWER SUPPLY Is the voltage more than 10 V Go to step 2 Check the harness 1 Disconnect the keyless entry control module for open circuits harness connector and shorts 2 Measure the voltage between the harness between the key connector terminal and chassis ground less entry control Connector amp terminal module and fuse B176 No 3 chassis ground CHECK GROUND CIRCUIT Is the resistance less than 10 The power supply Repair the har Measure the resistance between the harness Q and ground circuit ness connector terminal and chassis ground Connector amp terminal B176 No 8 chassis ground 6 CHECK IGNITION SWITCH CIRCUIT CHECK IGNITION SWITCH SIGNAL Is the voltage more than 10 V The ignition
14. M ama e a uM Un o _ Rear lid Console box Console pocket Upper bracket Pad Lower bracket El 11 13 14 15 16 BOO0302 Lock Front cover MT Boot Front cover AT EXTERIOR INTERIOR TRIM 14 INSTRUMENT PANEL GENERAL DESCRIPTION 1 2 4 5 6 7 8 Pad amp frame Center upper panel Air vent grille Defroster Grille cover Meter visor Defroster grille Cup holder Air vent grille Center 9 10 11 12 13 14 15 16 Air vent grille Side Lower cover Console cover Center panel Center pocket Ash tray Audio bracket Glove box lid El 12 BO0303 17 Glove box panel 18 Console rein forcement 19 Coin box Tightening torque N m kgf m ft lb 7 0 71 5 2 15 INNER TRIM SEDAN 1 2 3 4 5 Front pillar upper trim Center pillar upper trim Rear pillar upper trim Rear shelf trim Rear bulk trim GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM BO0380 Trunk rear trim 11 Side sill front cover Trunk side trim 12 Front garnish Rear pillar lower trim 13 Rear garnish Side sill rear cover Center pillar lower trim El 13 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 16 INNER TRIM WAGON 10 12 11 ifs LA TB W 81 1 Front pillar upper trim 6 Rear quarter lower trim 11 Side sill front cover 2
15. e Handle the bumper carefully to avoid damage to the bumper face Do not damage the body during removal or installation of bumper e To avoid damage to the bumper lay the re moved bumper on sheet spread on the floor Do not lay it directly on the floor 1 Disconnect the ground terminal from battery 2 Remove the bolts and clips 9 Remove the E A FORM from bumper beam CAUTION E A FORM may easily break Do not apply ex cessive force to it during removal 3 Remove the rear combination light assembly Ref to LI 18 REMOVAL Rear Combination Light Assembly 4 Remove the screw and two clips from each side 5 Remove the floor box 6 Remove the rear skirt trim EI 30 REAR BUMPER 11 Remove the canister lt Ref to EC SOHC 5 REMOVAL Canister gt 12 Remove the three bolts then remove the bumper beam 2 SEDAN Refer to rear bumper removal WAGON lt Ref to El 30 WAGON REMOVAL Rear Bumper gt B INSTALLATION 1 WAGON CAUTION e Handle the bumper carefully to avoid damage to the bumper face Do not damage the body during removal or installation of bumper 1 Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Description for tightening torque Hef to El 5 REAR BUMPER COMPONENT General Descrip tion 2 SEDAN CAUTION e Handle the bumper carefully to avoid damage to the bumper face Do not damage the
16. Do not drop the airbag modulator parts subject them to high temperature over 93 199 F or let water oil or grease get on them otherwise the in ternal parts may be damaged and reliability greatly lowered NO GOOD e The removed front seat with the airbag module must be kept at least 200 mm 8 in away from walls and other objects More than 200 mm 8 in e When storing a removed airbag module do not place any objects on it or pile airbag modules on top of each other If the airbag inflates for some rea son when it is placed with its pad side facing down ward or under any object a serious accident may result AB 6 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS Driver side GOOD Passenger side G5M0604 AB 7 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS Do not discard undeployed airbag modules They could easily cause a serious accident if acci dentally deployed B INSPECTION Before diagnosing check the following items that might be related to the engine problem 1 BATTERY Measure the battery voltage and specific gravity of electrolyte Standard voltage 12V Specific gravity Above 1 260 AB 8 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS C PREPARATION TOOL 1 SPECIAL TOOLS TEST HARNESS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FE020 TEST HARNESS M Used when measuring voltage resistance of air bag system RE0033 AB 9
17. OFF less than 12 If NG replace the main switch 2 SUB SWITCH Measure switch resistance Front passenger s door switch and rear door switch Switch position Standard ND than 12 OFF ess than TO DOWN jess than 10 If NG replace the sub switch GW 31 REAR WINDOW DEFOGGER GLASS WINDOWS MIRRORS 15 Rear Window Defogger A INSPECTION CAUTION When wiping stain on glass off with cloth use a dry and soft cloth and move it in the direction of the heat wire extension to avoid damage to the heat wire 1 Turn the ignition switch to ON 2 Turn the defogger switch to ON 3 Wrap the tips of tester pins with aluminum foil to avoid damage to heat wire _ Tester probe Heat wire Tin foil 4 Measure the voltage at wire center with DC volt meter Standard voltage Approx 6 volts B5M1053A Approx 6 V Approx 12 V or OV NOTE e if the measured value is 12 volts heat wire is open between wire center and positive end f zero volt heat wire is open between wire cen ter and ground 5 Apply positive lead of voltmeter to positive termi nal of voltmeter and then move negative lead along the wire up to the negative terminal end If voltage changes from zero to several volts during movement of lead heat wire is open at the voltage change point B REPAIR 1 Clean the broken portion with alcohol or white gasoline 2 Mask both side of wire with thin film
18. 200 W at 12 V Motor type Power consumption 70W at 12V Fan outer diameter 320 mm 12 6 in Motor type Magnet Power consumption 70Wat 12V Fan outer diameter 320 mm 12 6 in mode 850 100 rpm 278 29 kPa 2 83 0 3 kg cm 40 3 4 2 psi 287 3 55 kPa 2 9 9 o 5 kg cm 42 57 c psi 2 800 100 kPa 2931 kg cm 406415 psi 600 200 kPa 6 1242 kg cm 87429 psi Refrigerant i zl zl oO D zi ge D Condenser fan Sub fan Radiator fan Main fan Low pressure switch operating pressure OFF ON Dual switch Pressure switch l ON OFF High pressure switch operating pressure IP DIFF Diff 2 5 0 5 C 36 5 0 9 F Thermo control amplifier working temperature ON Evaporator outlet air 1 5 0 5 C 35 0 9 F AC 3 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C B COMPONENT 1 HEATER COOLING UNIT Seo 8 P Jn 15 10 8 HV0052 1 Unit cover 10 Heater core 19 Expansion valve 2 Side link 11 Drain hose 20 Evaporator 3 Mode acutuator lever 12 Mix acutuator lever 21 Evaporator cover 4 Foot lever 13 Unit assembly 22 Thermistor 5 Spring 14 Foot duct 6 Mode acutuator link 15 Clip Tightening torque N m kgf m ft lb 7 Defroster lever 16 Packing T 7 35 0 750 5 421 8 Foot nozzle 17 Cooling unit block 9 Unit duct cover 18 O ring
19. 3 Apply the conductive silver composition DU PONT No 4817 to the broken portion Broken portion Broken wire Masking thin film Conductive silver composition 4 After repair check wire GW 32 OUTER MIRROR ASSEMBLY GLASS WINDOWS MIRRORS 16 Outer Mirror Assembly B INSTALLATION A REMOVAL Install in the reverse order of removal 1 Disconnect the ground terminal from battery 2 Remove the door trim lt Ref to El 37 REMOV AL Front Door Trim gt 3 Remove the mirror gusset cover 4 Disconnect the mirror connector 5 Loosen the screws to remove mirror assembly GW 33 OUTER MIRROR ASSEMBLY GLASS WINDOWS MIRRORS C INSPECTION Check to ensure that the rearview mirror moves properly when the battery voltage is applied to ter minals Switch position ord LEFT If NG replace the mirror Mirror heater equipped model Switch position RM 8 and 7 C If NG replace the mirror GW 34 OUTER MIRROR 17 Outer Mirror A REPLACEMENT 1 Remove the door mirror assembly lt Ref to GW 33 REMOVAL Outer Mirror Assembly gt 2 Warm the area around the mirror holder with a hair drier until the edges of the mirror holder be come soft about 2 or 3 minutes with a 1 000 W dri er 3 Use a flat bladed screwdriver without sharp edg es to lift the mirror out of the mirror holder Also re move the connector from the back of mirrors with heaters
20. 7 i e nc 8 Rear Speake ERE TITO TTE DOPO 9 AMen Fs cr 10 GENERAL DESCRIPTION ENTERTAINMENT 1 General Description A CAUTION e Before disassembling or reassembling parts al ways disconnect the battery ground cable When replacing radio control module and other parts provided with memory functions record memory contents before disconnecting the battery ground cable Otherwise the memory will be erased e Reassemble in reverse order of disassembly un less otherwise indicated e Adjust the parts to the given specifications e Connect the connectors and hoses securely dur ing reassembly e After reassembly make sure functional parts op erate smoothly B PREPARATION TOOL 1 GENERAL TOOLS TOOL NAME REMARKS Circuit Tester Used for measuring resis tance and voltage ET 2 RADIO SYSTEM 2 Radio System A SCHEMATIC 1 RADIO lt Ref to WI 52 SCHEMATIC Audio System gt ET 3 ENTERTAINMENT RADIO SYSTEM ENTERTAINMENT INSPECTION No power coming in No display and no sound from speakers 1 Check fuse and power supply for radio 2 Check radio ground 3 Remove radio for repair A specific speaker does not operate 1 Check speaker 2 Check output circuit between radio and speaker Radio generates noise with engine running 1 Check radio ground 2 Check generator 3 Check ignition coil 4 Remove radio for repair 1 Check antenna 2 Check radio groun
21. 7 Check motor clutch drive Ref to CC 36 37 ACTUATOR MOTOR CLUTCH system Diagnostics Chart with Diagnostic Trouble Code gt Vehicle speed is not held 1 Check vehicle speed sen lt Ref to CC 30 DTC 22 VEHICLE SPEED SENSOR within set speed 3 km h 2 sor Diagnostics Chart with Diagnostic Trouble Code gt 2 Check motor drive sys lt Ref to CC 34 DTC 35 AND 36 ACTUATOR MOTOR tem Diagnostics Chart with Diagnostic Trouble Code gt 3 Check motor clutch drive Ref to CC 36 37 ACTUATOR MOTOR CLUTCH system Diagnostics Chart with Diagnostic Trouble Code gt 1 Check RESUME ACCEL Ref to CC 18 CHECK CRUISE CONTROL COM switch MAND SWITCH Diagnostics Chart with Symptom gt 2 Check motor drive sys lt Ref to CC 34 DTC 35 AND 36 ACTUATOR MOTOR Vehicle speed does not increase or does not return to set speed after RESUME ACCEL switch has been tem Diagnostics Chart with Diagnostic Trouble Code gt pressed 3 Check motor clutch drive Ref to CC 36 37 ACTUATOR MOTOR CLUTCH system Diagnostics Chart with Diagnostic Trouble Code gt Vehicle speed does not 1 Check SET COAST lt Ref to CC 18 CHECK CRUISE CONTROL COM decrease after SET COAST _ switch MAND SWITCH Diagnostics Chart with Symptom gt E switch has been pressed 2 Check motor drive sys Ref to CC 34 DTC 35 AND 36 ACTUATOR MOTOR tem Diagnostics Chart with Diagnostic Trouble Code
22. AB 67 AIRBAG SYSTEM DIAGNOSTICS Q TROUBLE CODE 52 DIAGNOSIS e Side airbag sensor LH is faulty e Side airbag harness LH is faulty e Airbag control module is faulty CAUTION DIAGNOSTIC CHART WITH TROUBLE CODE e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons e When inspecting the side airbag harness disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE SIDE AIRBAG INFLATOR SIDE LH AB 68 SENSOR LH B5M1106 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Check Yes CHECK SIDE AIRBAG HARNESS LH Is the resistance less than 10 Go to step 2 1 Turn the ignition switch OFF disconnect the 0 battery ground terminal and wait more than 20 seconds 2 Disconnect the connector AB21 from the seat belt pretensioner LH lt Ref to SB 8 Front Seat Belt gt 3 Disconnect the connector AB20 from AB19 4 Disconnect the connector AB
23. B INSTALLATION Install in the reverse order of removal El 56 TRUNK ROOM MAT EXTERIOR INTERIOR TRIM 28 Trunk Room Mat A REMOVAL Draw out the trunk room mat B INSTALLATION Install in the reverse order of removal El 57 TRUNK ROOM MAT EXTERIOR INTERIOR TRIM El 58 EXTERIOR BODY PANELS 1 2 3 4 5 6 8 9 General 6 a nt V 2 CORNET OOO Fender Panal ob etas tu uc Front Door eti m Moe fedus Po sd tia fd Ek Os URS Front Sealing A Ivan Dade Aue Ra ains E V EO UN UAE Rear DOOP aNG ete potus extus Ded ede E DON VEU Pal d aet Re DAP Panel ERR Bear Gale Panel uie ooi REPRE ORGAN ERU US eens GENERAL DESCRIPTION EXTERIOR BODY PANELS 1 General Description A SPECIFICATIONS a B dC NE D pce OU kD a f NC Ne N Wina i Front hood Front fender L is Front fender Front door SECTION A SECTION B Front door dil Rear door SECTION C Door panel Rear door AL c Side sill Rear quarter SECTION D SECTION E F BOO0260 Part Specification NA 4 0 mm 1 0 0 16 0 04 in Front hood to Front fender TURBO 3 7 mm 1 0 0 15 0 04 in
24. B6M1488A 1 LIGHTING SWITCH Switch postion OFF iere 14 and 16 Less than 10 Head 13 14andi6 Lessthan Q 2 DIMMER AND PASSING SWITCH Passing 7 8andi6 than 10 3 TURN SIGNAL SWITCH Nemd More 4 PARKING SWITCH Switch position Standard Less than 12 ON 1 and 4 Less than 1Q p A b SN Tete RUIT NE ET ESI IURIS T 3 Wm oe T t m AU NP TCR I T en HEADLIGHT ASSEMBLY LIGHTING SYSTEM 9 Headlight Assembly A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the duct A when right side headlight is removed ALTE Hp ARD 6 3 Remove the front grille and headlight side cover Ref to El 18 REMOVAL Front Grille and Ref to El 23 REMOVAL Front Bumper 4 Disconnect the headlight bulb connector 5 Remove three bolts and disconnect the connec tors and then detach the headlight assembly E N ur 11 BO0026 B INSTALLATION Install in the reverse order of removal C ADJUSTMENT 1 HEADLIGHT AIMING NOTE As this headlignt is the VISUAL AIMING it is possible to adjust aiming only in the vertical di rection It cannot be adjusted in the horizontal di rection CAUTION Turn off the light before adjusting headlight aiming If the light is necessary to check aim ing do no
25. CAUTION Use new TORX bolts during re assembly Install in the reverse order of removal C INSPECTION Check for the following and replace the damaged parts with new parts e Bracket connector for side airbag sensor is dam aged AB 16 ROLL CONNECTOR AIRBAG SYSTEM 9 Roll Connector A REMOVAL 1 Turn the ignition switch OFF 2 Disconnect the ground terminal from battery and wait for at least 20 seconds before starting work 3 Remove the driver s airbag module lt Ref to AB 12 Driver s Airbag Module gt 4 Remove the steering wheel lt Ref to PS 19 REMOVAL Steering Wheel gt 5 Remove the steering column cover 6 Remove the screws and then remove the roll connector B INSTALLATION 1 Install the roll connector and steering column cover in the reverse order of removal 2 Before installing steering wheel be sure the di rection of roll connector is adjusted with steering lt Ref to AB 17 ADJUSTMENT Roll Connector gt 3 Install the steering wheel and airbag module C INSPECTION Check for the following and replace the damaged parts with new parts e Combination switch and roll connector is cracked or deformed D ADJUSTMENT 1 Check that front wheels are positioned in straight ahead direction 2 Turn the roll connector pin A clockwise until it stops 3 Turn the roll connector pin A counterclockwise approximately 2 65 turns until A marks are aligned H
26. e The refrigerant is non toxic and harmless under normal operating circumstance but it may change to phosgene a noxious fume under open flames or high temperatures caused by a cigarette or heater e Provide good ventilation and do not work in a closed area e Never perform a gas leak test using a halide torch type leak tester e In order to avoid destroying the ozone layer pre vent HFC 134a from being released into the atmo sphere Using a refrigerant recovery system discharge and reuse it Goggles Gloves Avoid open No direct heat Do not flame on container discharge Loosen nn db AC 10 GENERAL DESCRIPTION 5 O RING CONNECTIONS Use new O rings e n order to keep the O rings free of lint which will cause a refrigerant gas leak perform operations without gloves and shop towels Apply the compressor oil to the O rings to avoid sticking then install them e Use a torque wrench to tighten the O ring fittings Over tightening will damage the O ring and tube end distortion e f the operation is interrupted before completing a pipe connection recap the tubes components and fittings with a plug or tape to prevent contamination from entering G4M0581 e Visually check the surfaces and mating surfaces of O rings threads and connecting points If a fail ure is found replace the applicable parts e Install the O rings at right angle to the tube beads HVAC SYSTEM HEATER VENTILATOR AN
27. ternal parts may be damaged and reliability greatly lowered G5M0295 e The removed front seat with the airbag module must be kept at least 200 mm 8 in away from walls and other objects More than 200 mm 8 in e When storing a removed airbag module do not place any objects on it or pile airbag modules on top of each other If the airbag inflates for some rea son when it is placed with its pad side facing down ward or under any object a serious accident may result AB 5 AIRBAG SYSTEM Driver side GENERAL DESCRIPTION tire Passenger side ZZTTTTITZIZT G5M0604 GENERAL DESCRIPTION AIRBAG SYSTEM C PREPARATION TOOL 1 GENERAL TOOL Used for removal of side airbag sensor AB 7 AIRBAG CONNECTOR AIRBAG SYSTEM 2 Airbag Connector A OPERATION 1 POWER SUPPLY 1 How to disconnect 1 Move the slide lock A in the direction of the arrow 2 Pull the female connector in the direction of the arrow with slide lock A moved CAUTION When pulling be sure to hold onto the connec tor and not the wire 2 How to connect Holding the connector A and push it in carefully until a connecting sound is heard A RE0013 CAUTION Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked 2 DRIVER S AIRBAG PASSENGER S AIR BAG SIDE AIRBAG 1 How to disconnect 1 Push the
28. 2 MPH Ref to CC 11 Symptom CHECK CRUISE CONTROL RELEASE OP 5 cruise control released after Go to step 10 Go to symptom 7 Symptom tics Chart with CHECK VEHICLE SPEED IS HELD WITHIN SET SPEED Make sure vehicle speed is held within set speed CHECK CRUISE CONTROL RELEASE OP ERATION Check cruise control release operation Is cruise control released after clutch pedal has been depressed MT Symptom CC 2 GENERAL DESCRIPTION CRUISE CONTROL SYSTEM DIAGNOSTICS 2 General Description CAUTION All Airbag system wiring harness and con A CAUTION nectors are colored yellow Do not use electri 1 SUPPLEMENTAL RESTRAINT SYSTEM cal test equipment on these circuits Be careful not to damage Airbag system wir L1 53 AIRBAG ing harness when servicing the cruise control Airbag system wiring harness is routed near the module and cruise control command switch cruise control module and cruise control command Switch B PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA150 CARTRIDGE Troubleshooting for electrical systems Newly adopted tool 22771AA030 SELECT MONITOR Troubleshooting for electrical systems KIT English 22771AA030 Without printer e German 22771AA070 Without printer e French 22771 AA080 Without printer Se Spanish of 2277
29. 2021122292025 REO054 AB 46 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS CHECK AIRBAG CONTROL MODULE 5 the voltage more than 10 V Replace the airbag to step 2 1 Turn the ignition switch OFF disconnect the ontrol module battery ground terminal and wait more than 20 Ref to AB 15 seconds irbag Control 2 Disconnect the connector AB6 from the air Aodule bag control module Ref to AB 15 Airbag Control Module 3 Connect the connector 11 in the test har ness or 12 to connector AB6 4 Connect the battery ground terminal and turn the ignition switch ON 5 Measure the voltage between connector 2l in the test harness or 12 and chassis ground Connector amp terminal 21 No 3 Chassis ground CHECK AIRBAG MAIN HARNESS 1 While checking control module turn the igni tion switch OFF and disconnect the battery ground terminal Wait more than 20 seconds before operation 2 Disconnect the airbag connector AB1 from the body harness B31 3 Connect the connector 2M in the test har ness M to connector AB1 4 Measure the resistance between connector 5M in the test harness M and the connector 21 in the test harness or 2 Connector amp terminal 5M No 2 21 No 3 CHECK AIRBAG MAIN HARNESS Measure the following resistance with the above mentioned condition maintained Connector amp terminal 5M No 2 Chassis ground 2
30. 4 Remove the seat belt lower anchor bolt B5M0814 5 Remove the anchor cover Remove the bolt and shoulder anchor from pillar 6 Remove the rear quarter trim Ref to E 47 REMOVAL Rear Quarter Trim 7 Remove the bolts and then detach the outer belt side SB 11 REAR SEAT BELT SEAT BELT SYSTEM 5 OUTER BELT CENTER WAGON 6 INNER BELT WAGON 1 Loosen the shoulder anchor bolt and then de 1 Remove the rear cushion tach the shoulder anchor from quarter pillar 2 Remove the bolt and then detach the inner belt 2 Remove the quarter trim lt Ref to El 47 RE MOVAL Rear Quarter Trim gt 3 Remove the three bolts and then detach the out er belt center SB 12 REAR SEAT BELT SEAT BELT SYSTEM B INSTALLATION 1 OUTER BELT SIDE SEDAN Install in the reverse order of removal CAUTION e During installation make sure that the seat belts are not twisted e After installation make sure that the seat belts can be smoothly extended and wound 2 OUTER BELT CENTER SEDAN Install in the reverse order of removal CAUTION e During installation make sure that the seat belts are not twisted e After installation make sure that the seat belts can be smoothly extended and wound 3 INNER BELT SEDAN Install in the reverse order of removal CAUTION During installation make sure that the seat belts are not twisted 4 OUTER BELT SIDE WAGON Install in the r
31. AIRBAG WARNING LIGHT REMAINS OFF DIAGNOSIS e Fuse No 13 in fuse box is blown e Body harness circuit is open e Airbag warning light is faulty e Airbag main harness is faulty e Airbag control module is faulty CAUTION Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the airbag main harness disconnect the airbag module connector of the driver and passenger seats for safety reasons WIRING DIAGRAM IG SW AIRBAG INDICATOR AIRBAG s BATTERY AIRBAG CONTROL MODULE REO052 AB 30 AIRBAG WARNING LIGHT FAILURE AIRBAG SYSTEM DIAGNOSTICS Ye Ne CHECK COMBINATION METER Do warning lights not for the Go to step 2 Repair the combi Turn the ignition switch ON and confirm that airbag turn on nation meter warning lights equipped in the combination power supply meter are turned on Ref to IDI 4 Combination Meter System CHECK FUSE NO 13 IN MAIN FUSE BOX 15 the fuse No 13 in main fuse Replace the fuse to step 3 Remove the fuse No 13 and perform visual box blown No 13 If the fuse inspection No 13 blows again go to
32. Canister 23 N m 2 3 kgf m 17 ft lb Lg 7 REAR DIFFERENTIAL PROTECTOR OPTION PARTS 5 Rear Differential Protector B INSTALLATION A REMOVAL Install in the reverse order of removal 1 Remove the rear exhaust pipe and muffer 2 Remove the differential front member installation bolts Tightening torque 70 N m 7 1 kgf m 51 6 ft lb NOTE 3 Loosen the nuts until the rear differential protec Install the protector between the nuts and differen tor can be removed tial rear member Tightening torque 70 N m 7 1 kgf m 51 6 ft Ib 4 Remove the rear differential protector OP 8 OPTION PARTS gt A S i a I a ERR C c RR Hc mA E EE RO 5 EE PO NOCH SU 2
33. METER 1 Disconnect the connector from the combina tion meter 2 Measure the resistance between the fuel sub level sensor harness connector terminal and combination meter harness connector termi nal Connector amp terminal R59 No 1 112 No 2 CHECK HARNESS BETWEEN FUEL LEVEL SENSOR AND FUEL SUB LEVEL SENSOR Measure the resistance between the fuel level sensor harness connector terminal and fuel sub level sensor harness connector terminal Connector amp terminal R58 No 3 R59 No 2 Repair the wiring harness 8 Chek Ye Is the resistance less than 10 2 Repair the wiring harness IDI 8 COMBINATION METER SYSTEM INSTRUMENTATION DRIVER INFO CHECK FUEL LEVEL SENSOR GROUND Repair the wiring CIRCUIT gauge lt Ref to harness Measure the resistance between the fuel level IDI 15 sensor harness connector terminal and chas REMOVAL Fuel sis ground Gauge Connector amp terminal R58 No 2 Chassis ground 7 CHECK ENGINE COOLANT TEMPERATURE SENSOR Ye Ne _ CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera Go to step 2 Replace the SENSOR engine coolant Check the engine coolant temperature sen temperature sen sor lt Ref to EN SOHC 120 DTC P0117 sor ENGINE COOLANT TEMPERATURE SEN SOR CIRCUIT LOW INPUT Diagnostic Procedure with Diagnostic Trouble Code DTC gt or lt Ref to EN DOHC TU
34. REO052 Repair the body Go to step 2 harness or replace the body harness with airbag main harness AB 28 AIRBAG WARNING LIGHT FAILURE AIRBAG SYSTEM DIAGNOSTICS check Ye We Is the airbag warning light Go to step 4 Go to step 3 turned off CHECK AIRBAG WARNING LIGHT 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Connect the connector 1M in the test har ness M to the body harness connector B31 3 Connect the battery ground terminal and turn the ignition switch ON 4 Connect two connectors 3M and 4M in the test harness M CHECK BODY HARNESS Is the anything unusual to body Repair the body Check the body harness harness harness NOTE After problem has been eliminated disconnect connectors 3M and 4M Replace combina tion meter printed circuit Ref to IDI 11 Combina tion Meter Assem bly gt Is the poor contact in connec Replace the body to step 5 Confirm that the firm contact is secured tor AB6 harness with air between the airbag control module and the bag main harness connector AB6 lt Ref to AB 15 Airbag Con or replace the air trol Module bag control mod ule lt Ref to AB 15 Airbag Control Module gt Go to step 6 CHECK POOR CONTACT CHECK AIRBAG MAIN HARNESS Is the airbag warnin
35. Ref to SL 35 Rear module and the Door Lock Actuator gt door lock actuator Rear gate latch lock actuator Ref to SL 38 Rear Gate Latch Lock Actuator SL 11 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 3 Keyless Entry System A SCHEMATIC 1 KEYLESS ENTRY lt Ref to WI 90 SCHEMATIC Keyless Entry Sys tem gt B ELECTRICAL SPECIFICATION 1 KEYLESS ENTRY CONTROL MODULE Content Measuring condition Integrated module 2 OUTPUT Battery voltage is present when pressing the transmitter LOCK ARM button one time Power supply Back up 3 Battery voltage is constantly present 3 Door lock switch 5 INPUT V is present when operating the door lock switch Trunk room light switch Sedan rear gate latch switch Wagon 6 INPUT V is present when opening the trunk lid or rear gate Ground 8 OVis constantly present Integrated module 9 OUTPUT Pun Ec when pressing the transmitter UNLOCK DIS Securly control module NN Security control module eo 10 1 V is present when pressing the transmitter UNLOCK DISARM or Horn relay 12 OUTPUT LOCK ARM button 3 Securly control module ee ignition switch ON Door unlock switch Key warning switch SL 12 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 2 INTEGRATED MODULE BO0311 Measuring condition Door switch Except driver s door 7 INPUT V is present when any door is open Except drive
36. Trouble Code gt e Airbag control module is faulty e Driver s airbag module is faulty e Airbag main harness circuit is open shorted or 12 Provided shorted to ground lt Ref to AB 38 TROU e Airbag module harness passenger circuit is BLE CODE 12 Diag l open shorted or shorted to ground nostic Chart with e Airbag control module is faulty Trouble Code gt e Passenger s airbag module is faulty Airbag main harness circuit driver is shorted to power supply e Airbag module harness driver is shorted to power i 2 Not provided 4 Not provided i lt Ref to AB 40 TROU BLE CODE 15 Diag nostic Chart with Trouble Code gt supply e Roll connector is shorted to power supply e Airbag control module is faulty e Driver s airbag module is faulty e Airbag main harness circuit passenger is shorted to power supply e Airbag module harness passenger is shorted to power supply e Airbag control module is faulty e Passenger s airbag module is faulty BB Ref to AB 42 TROU BLE CODE 16 Diag nostic Chart with Trouble Code Ref to AB 43 TROU BLE CODE 21 Diag nostic Chart with Trouble Code Ref to AB 44 TROU BLE CODE 22 Diag nostic Chart with Trouble Code Ref to AB 44 TROU BLE CODE 23 Diag nostic Chart with Trouble Code Ref to AB 46 TROU BLE CODE 24 Diag nostic
37. damage them 1 Disconnect the ground terminal from battery 2 Remove the rear door trim lt Ref to El 38 RE MOVAL Rear Door Trim gt 3 Remove the rear door glass lt Ref to GW 20 REMOVAL Rear Door Glass gt 4 Remove the rear door regulator and motor as sembly lt Ref to GW 22 REMOVAL Rear Regula tor and Motor Assembly gt 5 Remove the rear door latch lt Ref to SL 34 RE MOVAL Rear Door Latch Assembly gt 6 Remove the rear outer handle lt Ref to SL 33 REMOVAL Rear Outer Handle gt 7y Remove the center pillar lower trim Ref to El 46 REMOVAL Lower Inner Trim 8 Disconnect the connector of door harness 9 Put a wooden block on the jack and place the jack under the door Support the door with the jack to protect it EXTERIOR BODY PANELS 10 Remove the checker bolts 11 Remove the door side bolts for upper and lower hinges to remove door B INSTALLATION 1 Install in the reverse order of removal 2 Apply grease to sliding area of the door hinges Refer to COMPONENT of General Description for tightening torque Ref to EB 6 REAR DOOR PANEL General Description EB 15 REAR DOOR PANEL EXTERIOR BODY PANELS C ADJUSTMENT 1 Open the front door loosen the door side bolts of upper and lower hinges to align the position of rear door panel longitudinally and vertically f 2 Loosen the screw A and tap striker B using plastic hammer to adju
38. dia Symmetrical cal 86 Side frame gauge hole 18 mm 91 Strut mount attaching hole 10 mm 81 Side frame gauge hole 20 mm 0 71 in dia Symmetrical 0 39 in dia Symmetrical 0 79 in dia Symmetrical 87 Rear differential attaching hole 16 92 Sub frame attaching hole 16 mm 82 Front crossmember Ft attaching mm 0 63 in dia Symmetrical 0 63 in dia Symmetrical hole 12 4 mm 0 488 in dia 88 Rear suspension attaching hole 93 Bumper beam attaching hole Symmetrical 16 mm 0 63 in dia Symmetri Right 15 mm 0 59 in dia Left 19 83 Suspension attaching hole 17 mm x 15 mm 0 75 x 0 59 in dia 0 67 in dia Symmetrical 89 Rear side frame gauge hole 15 94 Side frame gauge hole 15 mm 84 Side frame gauge hole 20 mm mm 0 59 in dia Symmetrical 0 59 in dia Symmetrical 0 79 in dia Symmetrical BS 6 DATUM POINTS BODY STRUCTURE BS 7 DATUM POINTS BODY STRUCTURE LAN AK 6 SS LX 47 gt INS HES Ju fF ANA T A 2007 ao SET NS ail 65 T N OO DATUM POINTS es Ew BODY STRUCTURE SEDAN ee 76 0 X T BO0428 BO0432 BO0430 BO0434 BS 9 DATUM POINTS BODY STRUCTURE BS 10 DATUM DIMENSIONS 3 Datum Dimensions A MEASUREMENT Refer to LOCATION for details on measurement points lt Ref to BS 3 LOCATION Datum Points gt NOTE e
39. is faulty lt Ref to AB 58 TROU Provided Side airbag module RH is faulty BLE CODE 41 Diag Airbag control module is faulty nostic Chart with Trouble Code gt lt Ref to AB 60 TROU Side airbag harness LH is faulty Side airbag module LH is faulty Airbag control module is faulty BLE CODE 42 Diag nostic Chart with Trouble Code Ref to AB 62 TROU BLE CODE 45 Diag nostic Chart with Trouble Code Ref to AB 64 TROU BLE CODE 46 Diag nostic Chart with Trouble Code Ref to AB 66 TROU BLE CODE 51 Diag nostic Chart with Trouble Code Ref to AB 68 TROU BLE CODE 52 Diag nostic Chart with Trouble Code Ref to AB 69 TROU BLE CODE 53 Diag nostic Chart with Trouble Code Ref to AB 69 TROU BLE CODE 54 Diag nostic Chart with Trouble Code Ref to AB 70 TROU BLE CODE 55 Diag nostic Chart with Trouble Code Side airbag harness RH is shorted to power sup ply e Airbag control module is faulty e Side airbag harness LH is shorted to power sup ply e Airbag control module is faulty Side airbag sensor RH is faulty e Side airbag harness RH is faulty Airbag control module is faulty Side airbag sensor LH is faulty e Side airbag harness LH is faulty Airbag control module is faulty Side airbag sensor RH is faulty Pr
40. lt Ref to GW 17 AD JUSTMENT Front Door Glass GW 16 FRONT DOOR GLASS C ADJUSTMENT NOTE Before adjustment ensure that all adjusting bolts of stabilizer upper stopper and sash are loose and door glass is raised so that it is in contact with weatherstrip 1 Temporarily tighten one adjusting bolt on one side of rear sash at the midpoint of slotted hole in the inner panel 2 Temporarily tighten the regulator B channel in a position at the top of slotted hole 3 Lower the door glass 10 to 15 mm 0 39 to 0 59 in from fully closed position While applying out ward pressure of 45 0 4 9 N 4 6 0 5 kg 11 0 1 1 Ib F to upper edge of glass above midpoint of two outer stabilizers press the inner stabilizer at pres sure of 10 5 1 0 0 5 kg 0 2 0 1 Ib to the glass then secure it 10 15 mm 0 39 0 59 in Stabilizer 4 For adjustment of clearance between front glass and center pillar cover loosen the nuts A and move the glass sash back and forward until clear ance becomes the value shown Unit mm in GLASS WINDOWS MIRRORS 5 For adjustment of upper and lower ends of cen ter pillar loosen the adjusting nut A of B channel B5M0729A 6 Adjust so that the upper and lower ends of center pillar are the same size Glass tilts too far rearward 2 6 Ts Sf Lower B channel Glass tilts too far forward Raise B channel 7 For glass stroke adjustmen
41. ness Go to step 10 Replace the body harness with front sub sensor har ness RH Go to step 11 Replace the front sub sensor RH lt Ref to AB 18 Finish the diagno Front Sub Sen sis Is the resistance more than 1 MQ Is the resistance between 750Q and 1 SOr Replace the front sub sensor RH Ref to AB 18 Front Sub Sen sor gt Is the resistance more than 1 MQ AB 52 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS AB 53 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS K TROUBLE CODE 32 DIAGNOSIS e Front sub sensor harness LH circuit is shorted e Front sub sensor harness LH circuit is open e Front sub sensor LH is faulty e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE FRONT SUB SENSOR LH 11213 gt lt asia s s 15
42. sill cep ete ee Keyless entry control module 7 Keyless entrycontrolmodule OCS LLL Security indicator light 9 OUTPUT V is present when activating the alarm operation Keyless entry control module 11 Power supply for clearance light Back up Battery voltage is constantly present Clearance gh Power supply Backup Ground interrupt relay Security hom relay Security hom Security horn relay 18 INPUT Battery voltage is present when activating the alarm operation 4 51 21 SECURITY SYSTEM SECURITY AND LOCKS C INSPECTION 1 BASIC DIAGNOSTIC PROCEDURE Ye Ne 1 CHECK SECURITY SYSTEM SET OPERA the security system be Go to step 2 Go to symptom 1 TION set lt Ref to SL 23 1 Before starting this diagnosis open all win SYMPTOM dows CHART INSPEC 2 Remove the key from ignition key cylinder and then close all doors and rear gate or trunk lid 3 Press the LOCK ARM button of transmitter CHECK SECURITY INDICATOR LIGHT AND CLEARANCE LIGHT BLINKING Check the security indicator light and clear ance light blinking TION Security System Do the security indicator light and clearance light blink Go to step 3 Go to symptom 2 lt Ref to SL 23 SYMPTOM CHART INSPEC TION Security System Go to step 4 CHECK SECURITY ALARM OPERATION 1 Unlock all doors using the door lock swit
43. 0 47 in dia Symmetrical Outer panel center pillar gauge hole 12 mm 0 47 in dia Sym metrical Outer panel center pillar gauge hole 12 mm 0 47 in dia Sym metrical Weather strip patch attaching hole 5 2 mm 0 205 in dia Symmetri cal BS 3 24 62 70 71 73 74 75 BO0404 Roof panel repair locator hollow Belt anchor attaching hole 11 mm 0 43 in dia Symmetrical Trim clip attaching hole 8 5 mm 0 335 in dia Symmetrical Harness clip attaching hole 7 mm 0 28 in dia Symmetrical Harness clip attaching hole 7 mm 0 28 in dia Symmetrical Trim clip attaching hole 10 mm 0 39 in dia Symmetrical Insulator attaching hole 8 mm 0 31 in dia Symmetrical DATUM POINTS BODY STRUCTURE 2 WAGON REAR SECTION 30 Child anchor attaching hole 11 33 Two striker attaching hole 15 67 Gusset floor rear side gauge hole mm 0 43 in dia 0 59 in dia 11 5 mm 0 453 in dia Symmet 31 Washer hose attaching hole Left 7 58 Rear bumper plate nut attaching rical mm 0 28 in dia hole 11 mm 0 43 in dia Sym 72 Trim upper clip attaching hole 8 5 32 Rear combination light mounting metrical mm 0 335 in dia Symmetrical hole 7 mm 0 28 in dia Symmet 65 Floor mat clip attaching hole 8mm 77 Harness clip attaching hole 7 mm rical 0 31 in dia 0 28 in dia Symmetrical BS 4 3 SEDAN REAR SECTION 50 Repair locator ho
44. 16 17 22 23 2 os s 2728 REO056 AB 54 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Sep eck ves 1 CHECK FRONT SUB SENSOR LH AND 5 the resistance between 30 to step 2 Go to step 3 FRONT SUB SENSOR HARNESS RH 50Q and 1 1 Turn the ignition switch OFF disconnect the Go to step 5 battery ground terminal and wait more than 20 seconds 2 Disconnect the connector AB6 from the air bag control module and connect connector 11 in the test harness or I2 to the connector AB6 lt Ref to AB 15 Airbag Control Mod ule gt 3 Measure the resistance of the connector 31 in the test harness or I2 Connector amp terminal 31 No 1 No 3 CHECK FRONT SUB SENSOR LH AND FRONT SUB SENSOR HARNESS RH Measure the resistance between connector 31 in the test harness or I2 and the chassis ground Connector amp terminal 31 No 1 Chassis ground 31 No 3 Chassis ground CHECK AIRBAG MAIN HARNESS AND FRONT SUB SENSOR HARNESS LH 1 Disconnect the connector AB13 from the front sub sensor Ref to AB 18 Front Sub Sensor 2 Connect the connector 1H in the test har ness H to the connector AB13 3 Measure the resistance between connector 3l in the test harness or 12 and connector 3H in the test harness H Connector amp terminal 31 No 3 3H No 6 31 No 1 3H No 5 CHECK AIRBAG MAIN
45. 2 with a new one In 3 Attach the metal washer A only to bolt 6 At stall the clip with arrow mark facing the front side of tach the foam rubber washer B to bolt 6 7 8 grille A 2 Replace the white clip 3 4 5 with a new one Install the white clip 3 4 by aligning the rib of clip parallel with the grille front rear direction A CAUTION Do not use foam rubber washer with new white clips El 20 HOOD GRILLE EXTERIOR INTERIOR TRIM 4 Insert the hood grille clip and engage the five 7 Install the hood duct with clip A and seven clips bolts CAUTION Make sure that the anchor portion of each clip is firmly engaged 5 Install the three nuts Tightening torque 4 4 0 45 kgf m 3 25 ft lb INSPECTION Make sure that the clip is firmly engaged Make sure that there is no abnormal gap at whole periphery of hood grille Make sure that there is no damage on hood grille 6 Catch the two hooks of hood duct to the hood holes El 21 FRONT UNDER COVER EXTERIOR INTERIOR TRIM 4 Front Under Cover A REMOVAL 1 Lift up the vehicle 2 Loosen the bolts and clips to remove the under cover B INSTALLATION Install in the reverse order of removal El 22 FRONT BUMPER 5 Front Bumper A REMOVAL CAUTION e Handle the bumper carefully to avoid damage to the bumper face Do not damage the body during removal or installation of bu
46. 5 kg cm 36 50 psi Leave unattended at 20 C 68 F for at least 10 Leave unattended Not required e Spraying pressure 245 343 kPa minutes until the topcoated area is half dry 21 Top coat Il Not required 2 5 3 5 kg cm 36 50 psi NOTE Be careful to keep dust or dirt from coming in contact with the affected area Allow the coated surface to dry at 20 C 68 F for two hours or 60 C 140 F for 30 minutes Drying NOTE Do not allow the temperature to exceed 80 C 176 F since this will deform the PP substrate Carefully check the condition of the repaired area Masking removal Remove the masking tape applied in Process No 11 and 13 Apply a clear coat three times at an interval of 3 to 5 minutes 25 Parts installation Install parts on the bumper in reverse order of removal 26 Bumper installation Install the bumper EXTERIOR INTERIOR TRIM 19 Top coat 1 NO Recommended paint C710 Overlay Clear No 307 Flex Hardener SC Reducer thinner e Mixing ratio 3 1 Suncryl SC vs No 307 Flex Hardener e Viscosity 10 13 sec 20 C 68 F e Coated film thickness 20 30u 22 23 24 El 29 REAR BUMPER EXTERIOR INTERIOR TRIM 6 Rear Bumper 7 Pull off the rear end of rear quarter lower trim and then loosen the two nuts from each side to re A REMOVAL move the rear bumper 1 WAGON CAUTION
47. A B INSTALLATION Install is in the reverse order of removal CC 6 C INSPECTION Measure the cruise control main switch resistance Main switch side 2 3 5 Switch position Standard More than TMG L ON sands ess than If NG replace the cruise control main switch CRUISE CONTROL COMMAND SWITCH CRUISE CONTROL SYSTEM 5 Cruise Control Command Switch A REMOVAL WARNING Before servicing be sure to read the notes in the AB section for proper handling of the driv er s airbag module lt Ref to AB 3 CAUTION General Description gt 1 Set the front wheels in straight ahead position 2 Turn ignition switch OFF 3 Disconnect the ground terminal from battery and wait for at least 20 seconds before starting work 4 Using TORX BIT T30 Tamper resistant type loosen two TORX bolts which secure driver s air bag module TORX BIT T30 H5M0662A 5 Disconnect the airbag module connector on back of the airbag module 6 Remove the horn switch from the steering wheel as shown 7 Disconnect the horn and cruise control com mand switch connector then remove the cruise control command switch B INSTALLATION Install is in the reverse order of removal C INSPECTION Measure the cruise control command switch resis tance Standard CANCEL and 2 Less than 1Q 1 1 3 Less than 10 FF inan 1M SET COAST 1 an
48. A C Front door to Rear door 5 0 mm 0 20 in Rear door to Rear quarter 4 6 mm 0 18 in EF EF Door panel to Side sill 5 9 mm 0 23 in B Frontfender to Front door 4 6 mm 1 0 0 18 0 04 in EB 2 GENERAL DESCRIPTION EXTERIOR BODY PANELS B COMPONENT 1 FRONT HOOD BO0364 1 Front hood 6 Clip Tightening torque N m kgf m ft Ib 2 Seal Front panel 7 Locking piece T 7 35 0 75 5 4 3 Hinge 8 Seal Intake duct T1 24 5 2 5 18 1 4 Hood grille Only turbo model 5 Packing 9 Seal Hood EB 3 GENERAL DESCRIPTION EXTERIOR BODY PANELS 2 FRONT FENDER PANEL BO0321 1 Front fender panel Tightening torque N m kgf m ft lb T 7 35 0 75 5 4 EB 4 3 FRONT DOOR PANEL Gusset 1 2 Weatherstrip Outer 3 Clip Weatherstrip outer 4 Stabilizer Outer 5 Stabilizer Inner GENERAL DESCRIPTION sealing cover Checker Lower hinge Upper hinge Door panel Soo oo Sf gt EB 5 EXTERIOR BODY PANELS 7 4 0 75 5 5 24 5 2 49 18 29 4 3 0 21 7 32 3 3 29 23 8 BOO0365 Tightening torque N m kgf m ft Ib T1 T2 T3 T4 GENERAL DESCRIPTION EXTERIOR BODY PANELS 4 REAR DOOR PANEL Weatherstrip Outer Clip Weatherstrip outer Stabilizer Outer Stabilizer Inner eatin Grm A W N M t BOO0366 Tightening torque N m kgf m ft Ib T1 T2
49. A uses ux d 2 2 Front SCA auc voee 6 11 Roar a E GENERAL DESCRIPTION SEATS 1 General Description A COMPONENT 1 FRONT SEAT BO0354 1 Front seat ASSY 6 Seat hinge Tightening torque kgf m ft lb 2 Rail cover IN 7 Seat hinge cover T1 24 5 2 5 18 3 Rail cover OUT 8 Seat lifter lever T2 30 3 1 22 4 Slide rail OUT 9 Reclining lever T3 53 5 4 39 5 Slide rail IN SE 2 GENERAL DESCRIPTION SEATS 2 REAR SEAT SEDAN BO0355 _ 1 Backrest 4 Armrest Tightening torque N m kgf m ft Ib 2 Head restraint 5 Center through frame T 24 5 2 5 18 1 3 Cushion 6 Hook SE 3 GENERAL DESCRIPTION SEATS 3 REAR SEAT WAGON BO0247 1 Cushion 4 Head restraint Tightening torque N m kgf m ft Ib 2 Backrest RH b Striker T 24 5 2 5 18 1 3 Backrest LH SE 4 GENERAL DESCRIPTION SEATS B CAUTION e While loading to or unloading to the vehicle take e Take care not to contaminate or damage seat care not to contact body mE surface When removing the front seat from a side airbag loaded vehicle follow cautions given in the airbag section C PREPARATION TOOL 1 GENERAL TOOL TOOL NAME REMARKS Long Nose Pliers Used for removing and installing the hog ring FRONT SEAT SEATS 2 Front Seat 8 Remove the two bolts at front
50. AC 4 2 BLOWER MOTOR UNIT GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 1 2 3 4 5 Upper case Blower link Blower link lever A Blower link lever B Clip 6 7 8 9 10 HV0053 Filter cover Tightening torque N m kgf m ft Ib Filter T 7 35 0 750 5 421 Blower motor assembly Hose Blower resistor AC 5 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 3 CONTROL UNIT 1 2 3 4 5 Dial Fan control plate Temperature control plate Mode control plate Heater control knob 6 10 Heater control panel Air conditioner knob Plug knob Heater control base Intake cable AC 6 11 12 13 14 15 Mode cable Temperature cable Bulb Fan switch ASSY Harness 4 AIR CONDITIONING UNIT 1 2 3 4 5 Condenser Hose High pressure Hose Low pressure Bracket Compressor GENERAL DESCRIPTION 6 7 8 9 10 HVAC SYSTEM HEATER VENTILATOR AND A C HV0055 O ring Tightening torque N m kgf m ft lb Clamp A T1 7 4 0 75 5 4 Clamp B T2 15 1 5 10 8 Tube To condenser Tube To evaporator AC 7 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 5 COMPRESSOR 1 Idler pulley bracket 7 V belt Tightening torque N m kgf m ft Ib 2 Idler pulley adjuster 8 X Compressor belt cover 1 7 4 0 75 5 4 3 idler pulley T2 22 6 2 3 16 6
51. AND LOCKS 8 CHECK SECURITY HORN NM CHECK SECURITY HORN RELAY Is the security horn relay OK Replace the secu Remove and check the security horn relay rity horn relay Go to step 3 Check the harness for open circuits and shorts between the secu rity horn relay and horn relay Ref to SL 47 Security Horn Relay CHECK POWER SUPPLY FOR SECURITY Is the voltage more than 10 V HORN RELAY Measure the voltage between the security horn relay harness connector terminal and chassis ground Connector amp terminal B243 No 1 chassis ground CHECK POWER SUPPLY FOR SECURITY HORN RELAY Measure the voltage between the security horn relay harness connector terminal and chassis ground Connector amp terminal B243 No 2 chassis ground CHECK HARNESS BETWEEN SECURITY HORN RELAY AND SECURITY CONTROL MODULE 1 Disconnect the security control module har ness connector 2 Measure the resistance between the security horn relay harness connector terminal and security control module harness connector ter minal Connector amp terminal B243 No 3 B93 No 18 CHECK HARNESS BETWEEN SECURITY 5 the resistance less than 10 HORN RELAY AND SECURITY CONTROL Q MODULE Measure the resistance between the security horn relay harness connector terminal and security control module harness connector ter minal Connector amp terminal B243
52. Air conditioning relay Magnet clutch Compressor Pressure switch A C switch Blower switch Wire harness V Belt Magnet clutch Compressor Refrigerant V Belt Magnet clutch Compressor Pressure switch A C switch Blower switch Wire harness Heater duct Heater vent duct Engine coolant Blower switch Heater core Engine coolant Mode actuator Wire harness Mode actuator Air flow switch Wire harness Air inlet select switch FRESH RECIRC actuator Wire harness AC 36 AIRBAG SYSTEM t General DescripllOn essen eddie vto 2 CONMOCION oio usi p 3 Inspection Locations After a Collision 4 Drivers Airbag Module ee ence t eee Maa el e urba Up DA Gp 5 Passenger s Airbag Module 6 Side Airbag MOGOUIG oi o eo RED ERO Ve n es obo 7 Airbag Control Module thx bn ER Eo EXER CDU 8 Side Airbag SEASON Sugeest Elba a 9 Boll GOneclor eere eoe necem ote inta ep dp exe admin SEU pront 5ub Sensor ni ie oU eset RE e mr ea GENERAL DESCRIPTION AIRBAG SYSTEM 1 General Description A COMPONENT RE0031 1 Combination switch ASSY with roll 7 Side airbag sensor Tightening torque N m kgf m ft Ib connector 8 Side airbag harness 1 7 4 0 75 5 4 2 TORX boit
53. Chart with Trouble Code Ref to AB 48 TROU BLE CODE 25 Diag nostic Chart with Trouble Code Ref to AB 50 TROU BLE CODE 31 Diag nostic Chart with Trouble Code Airbag control module is faulty Front airbag module and seat belt pretensioner LH RH are inflated AB6 AB17 and AB18 are not connected prop erly to airbag control module e Airbag control module is faulty Airbag main harness circuit is open e Fuse No 11 in joint box is blown e Body harness circuit is open e Airbag control module is faulty e Airbag main harness circuit is open e Fuse No 6 in joint box is blown e Body harness circuit is open NO Q3 e Front sub sensor harness RH circuit is shorted e Front sub sensor harness RH circuit is open J J Front sub sensor RH is faulty Airbag control module is faulty AB 32 Trouble code Contents of troubles 4 NO Q3 D ho eo C Ci NO LIST OF DIAGNOSTIC TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Memory Contents of diagnosis Index No function Front sub sensor harness LH circuit is shorted lt Ref to AB 54 TROU Provided Front sub sensor harness LH circuit is open BLE CODE 32 Diag i Front sub sensor LH is faulty nostic Chart with Airbag control module is faulty Trouble Code gt Side airbag harness RH
54. Circuit Used for measuring resistance and voltage Tester ee a Ty COM 2 Mio L A ee is Dios ir afe bna re E indc E a oM a Lai cort ara HORN SYSTEM 2 Horn System A SCHEMATIC 1 HORN lt Ref to WI 89 SCHEMATIC Horn System gt B INSPECTION 1 HORN RELAY Measure the horn relay resistance between termi nals indicated in table below when connecting ter minal No 4 to battery positive terminal and terminal No 3 to battery ground terminal Standard More than 1MQ COM 3 COMMUNICATION SYSTEM HORN COMMUNICATION SYSTEM 3 Horn A REMOVAL 1 Disconnect the battery ground cable 2 Remove the horn bracket mounting bolt A 3 Disconnect the harness connector and remove the horn assembly B B INSTALLATION Install in the reverse order of removal C INSPECTION With 12 V direct current supply between horn termi nal and case ground check that the horn sounds properly COM 4 HORN SWITCH 4 Horn Switch A REMOVAL WARNING Before servicing be sure to read the notes in the AB section for proper handling of the driver airbag module lt Ref to AB 3 CAUTION Gen eral Description gt 1 Disconnect the battery ground cable 2 Remove the driver s airbag module lt Ref to AB 12 Driver s Airbag Module gt 3 Remove the horn switch from the steering wheel as shown COMMUNICATION SYSTEM C INSPECT
55. EV 26 Airbag Warning Light UM ER dou 27 List of Diagnostic Trouble Code esee 32 Diagnostic Chart with Trouble Code 36 BASIC DIAGNOSTIC PROCEDURE AIRBAG SYSTEM DIAGNOSTICS 1 Basic Diagnostic Procedure A PROCEDURE Read Diagnostic Trouble Code lt Ref to AB 24 Read Diagnostic Trouble Code gt Read Diagnostic Trouble Code lt Ref to AB 24 Read Diagnostic Trouble Code gt Perform the diagnosis 1 Judge the possible cause from List of Diag nostic Trouble Code lt Ref to AB 32 List of Diagnostic Trouble Code 2 Inspect using Diagnostic Chart with Trouble Code DTC 3 Repair the cause of the trouble 4 Perform the clear memory mode Ref to AB 26 Clear Memory Mode 5 Perform the inspection mode Ref to AB 25 Inspection Mode 6 Read diagnostic trouble code Is the normal code being detected Is the trouble code being detected Is the trouble code being detected AB 2 Finish the diagno Go to step 2 sis Go to Airbag Warning Light Fail ure Ref to AB 27 Airbag Warn ing Light Failure Perform the proce Finish the diagno Go to step 3 dure 1 to 5 in sis step 3 CHECK LIST FOR INTERVIEW AIRBAG SYSTEM DIAGNOSTICS 2 Check List for Interview A CHECK Customer s Name Inspector s Name Registration No Date Veh
56. HARNESS AND FRONT SUB SENSOR HARNESS LH Measure the resistance between connector 31 in the test harness or I2 and the chassis ground Connector amp terminal 31 No 3 Chassis ground 31 No 1 Chassis ground CHECK AIRBAG MAIN HARNESS 1 Disconnect the connector AB11 from AB12 and connect the connector 1F in the test harness F to AB11 2 Measure the resistance between connector 31 in the test harness or 12 and connector in the test harness F Connector amp terminal 31 No 3 3F No 3 31 No 1 3F No 4 CHECK AIRBAG MAIN HARNESS Measure the resistance between connector 31 in the test harness or I2 and the chassis ground Connector amp terminal 3I No 3 Chassis ground 31 No 1 Chassis ground s the resistance more than 1 AQ Replace the airbag ontrol module lt Ref to AB 15 irbag Control Vodule s the resistance less than 10 2 3o to step 4 s the resistance more than 1 30 to step 10 AQ Go to step 5 s the resistance less than 10 to step 6 2 Replace the body harness with air bag main harness s the resistance more than 1 3o to step 7 AQ Replace the body harness with air bag main harness AB 55 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Check
57. LI 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one 1 22 LICENSE PLATE LIGHT LIGHTING SYSTEM 21 License Plate Light A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the license plate light mounting screw A and then remove the lens B 3 Remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description gt 3 If NG replace the bulb with a new one Li 23 HIGH MOUNTED STOP LIGHT LIGHTING SYSTEM 22 High mounted Stop Light A REMOVAL 1 SEDAN 1 Disconnect the ground terminal from battery 2 Disconnect the connector of high mounted stop light from body harness 3 Remove the bolts then detach the high mounted stop light assembly 2 WAGON 1 Disconnect the ground terminal from battery 2 Remove the screws A and then detach the cov er B 3 Remove the screws C and then detach the high mounted stop light while disconnecting the connector B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description gt 3 If NG replace the bulb with a new one Ll 24 E Me REA v CI eR REQUE S ND eee
58. Maskin Mask specified part black base with masking tape Use masking tape for PP example Nichiban 9 533 no M cigan Clean all parts to be painted with white gasoline normal alcohol etc to remove dirt oil fat etc Apply primer one to all parts to be painted using air gun Use primer clear Dry at normal temperature 10 to 15 min at 20 C 68 F 5 Drying 2 3 4 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 Solid color Metallic color Use section block paint for top coat Use section block paint for top coat e Paint in use for each color e Paint in use for each color o Solid paint Metallic paint Hardener PB Hardener PB Thinner T 301 Thinner 1 306 Top coat paint l e Mixing ratio Main agent vs hardener 4 1 e Viscosity 10 13 sec 20 C 68 F e Film thickness 35 45u e Spraying pressure 245 343 kPa 2 5 3 5 kg cm 36 50 psi 7 Drying Not required e Spraying pressure 245 343 kPa Top coat paint Il Not required 2 5 3 5 kg cm 36 50 psi 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 inspection Masking removal e Mixing ratio Main agent vs hardener 10 1 e Vi
59. Mirror holder B5M1144A 4 Warm the area around the mirror holder with a hair drier until the edges of the mirror holder be come soft about 2 or 3 minutes with a 1 000 W dri er 5 Remove the backing of the new two sided tape and push the mirror in to install it CAUTION Uniess the mirror holder is warmed sufficiently the mirror holder edges may be damaged or the mirror cracked GW 35 GLASS WINDOWS MIRRORS REMOTE CONTROL MIRROR SWITCH GLASS WINDOWS MIRRORS 18 Remote Control Mirror B INSTALLATION Switch Install in the reverse order of removal A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the console cover 3 Disconnect the connector GW 36 REMOTE CONTROL MIRROR SWITCH GLASS WINDOWS MIRRORS C INSPECTION Move the rearview mirror switch to each position and measure switch resistance alal 8 7 16 5 1132 Change over switch left position Switch postion OFF UP 4 and 8 2 and 1 less than 10 RIGHT 8 and 2 4 and 1 less than 192 Change over switch right position If NG replace the switch GW 37 REMOTE CONTROL MIRROR SWITCH GLASS WINDOWS MIRRORS GW 38 BODY STRUCTURE Refer to G1831BE SUPPLEMENT for this section BS Page BODY STRUCTURE 1 General Description np r 2 2 datum Polis ocio edere iE Cena tr PR
60. No 4 B93 No 16 CHECK HARNESS BETWEEN SECURITY Is the resistance less than 10 CONTROL MODULE AND SECURITY HORN 1 Disconnect the security horn harness con nector 2 Measure the resistance between the security control module harness connector terminal and security horn harness connector terminal Go to step 6 Check the harness for open circuits and shorts between the secu rity horn relay and security control module Go to step 7 Check the harness for open circuits and shorts between the secu rity control module and security horn Connector amp terminal B93 No 17 B204 No 1 CHECK SECURITY HORN Is the security horn OK Replace the secu Replace the secu Remove and check the security horn Ref to rity control mod horn 5 the voltage more than 10 V Go to step 4 Check the harness for open Circuits and shorts between the secu rity horn relay and the fuse Go to step 5 Check the harness for open circuits and shorts between the secu rity horn relay and security control module Is the resistance less than 10 Q SL 46 Security Horn gt ule SL 26 SECURITY SYSTEM SECURITY AND LOCKS 9 CHECK CLEARANCE LIGHT OPERATION CHECK CLEARANCE LIGHT OPERATION Does the clearance light illumi Go to step 2 Check the clear Turn the parking switch ON and check if the nate ance light circuit clearance light illuminate
61. Remove the electrical connector from the rear defogger terminal 3 Remove the glass in the same procedure as for windshield glass lt Ref to GW 23 REMOVAL Windshield Glass gt B INSTALLATION 1 Apply the adhesive evenly to the glass attach ment area 2 Insert the glass clip pin into the rear gate hole and after pushing on the area around the clip pin to secure it push lightly all around the area to seal it 3 About one hour after installation conduct a leak test Upper side Molding Adhesive Lower side Adhesive Molding CAUTION When door is opened closed after glass is bonded always lower door glass and then open close it carefully e Move vehicle slowly 4 After completion of all work allow vehicle to stand for about 24 hours NOTE For minimum drying time and time the vehicle must be left standing before driving after bonding follow instructions or instruction manual from the adhe sive manufacturer CAUTION When a vehicle is returned to the user tell him or her that the vehicle should not be subjected to heavy impact for at least three days 5 Connect the rear defogger terminals 6 Install the rear wiper Ref to WW 17 INSTAL LATION Rear Wiper Motor GW 26 REAR QUARTER GLASS 11 Rear Quarter Glass A REMOVAL GLASS WINDOWS MIRRORS Remove the glass in the same procedure as for windshield glass lt Ref to GW 23 REMOVAL Windshield Glass gt Mat
62. SEAT 1 Remove the seat from the vehicle lt Ref to SE 6 REMOVAL Front Seat gt 2 Remove the hook at bottom of seat back rest SE 8 FRONT SEAT SEATS 6 Loosen four bolts to remove the seat cushion 9 Remove the hog rings and then remove the seat back rest cover Without side airbag model With side airbag model 9 Hog ring 10 Remove the hog rings and then remove the seat cushion cover Standard type model B5M0958A SE 9 FRONT SEAT SEATS ASSEMBLY 1 DRIVER S SEAT Assemble in the reverse order of disassembly NOTE e Do not contaminate or damage the cover e While installing the hog rings prevent the seat from getting wrinkled 2 PASSENGER S SEAT Assemble in the reverse order of disassembly NOTE e Do not contaminate or damage the cover e While installing the hog rings prevent the seat from getting wrinkled SE 10 REAR SEAT SEATS 3 Rear Seat 2 SEDAN 1 Remove the bolts and then detach rear seat A REMOVAL ae 1 WAGON 1 Remove the bolts and then detach rear seat cushion aal 2 2 Remove the headrest 3 Remove the luggage floor mat Ref to El 56 REMOVAL Luggage Floor Mat 4 Turn over the mat to remove bolts he JS 5 Remove the rear seat backrest Ai 9 WOO MAN TERR lt BO0174 2 Remove the bolts securing lower portion of back rest and
63. T3 T4 7 4 0 75 5 5 24 5 2 49 18 29 4 3 0 21 7 32 3 3 29 23 8 GENERAL DESCRIPTION EXTERIOR BODY PANELS 5 TRUNK LID PANEL BO0251 1 Torsion bar 4 Hinge ASSY Tightening torque kgf m ft lb 2 Trunk lid T1 7 5 0 76 5 5 3 Weatherstrip 2 14 1 8 13 7 GENERAL DESCRIPTION EXTERIOR BODY PANELS 6 REAR GATE PANEL BO0367 Tightening torque N m kgf m ft lb 1 Gas stay 2 Hinge T 14 1 43 10 3 3 Rear gate 1 25 2 5 18 1 C CAUTION e Exterior body panels are heavy Do not drop and damage the panels During removal and installa tion do not damage the panel painting surface e While removing mounting bolts using assistance devices such as a support jack will help support the panel e Be careful not to lose small parts EB 8 GENERAL DESCRIPTION EXTERIOR BODY PANELS D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925610000 WRENCH Used for removing and installing door hinge Q2 B5M1117 927780000 REMOVER B5M1118 2 GENERAL TOOL TOOL NAME REMARKS Support Jack Used for supporting door panel Used for removing and installing trunk torsion bar EB 9 FRONT HOOD EXTERIOR BODY PANELS 2 Front Hood 2 Adjust the height at front end of hood lt Ref to SL 41 ADJUSTMENT Front Hood Lock Assem A REMOVAL bly gt 1 Open the front hood to remove the washer noz 3 Rot
64. Trim 24 Rear Shelf Trim idea kr iii 25 TUAK TU TE o bat Ex E eas oia ede eto etes 20 didi RTL 2f Luggage Floor ioc 28 Trunk Room GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 1 General Description A COMPONENT 1 FRONT GRILLE 1 Front grille 2 Front grille emblem 3 Clip 2 UNDER COVER 1 Under cover 3 Clip Tightening torque N m kgf m ft Ib 2 Clip side T 14 1 42 10 3 El 2 3 HOOD GRILLE Hood grille Bolt Metal washer Foam rubber washer Grille duct Grille lower duct GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM Clip Tightening torque N m ft lb Black clip T 4 4 0 45 3 25 White clip Packing Packing El 3 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 4 FRONT BUMPER 1 2 3 4 Bumper face B License plate bracket Head light side cover 6 Bumper energy absorber Bumper side bracket 7 Bumper back beam Bumper corner bracket El 4 BOO281 Tightening torque N m kgf m ft Ib Ti 32 3 3 24 T2 69 7 0 51 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 5 REAR BUMPER BOO282 1 Bumper face 5 Bumper side cover Tightening torque N m kgf m ft lb 2 Bumper upper beam 6 License plate base T1 33 3 4 24 3 Bumper corner bracket 7 Bumper energy absorber T2 34 3 5 25 4 Bumper
65. Trim 2 Remove the front mole A 3 Remove the front pillar upper trim B 4 Detach the front seat belt shoulder anchor then remove the center pillar upper trim C B Q Hook B5M1021A B INSTALLATION Install in the reverse order of removal CAUTION Be sure to securely hook pawls of inner trim panel to body flange NOTE When installing the center pillar upper trim and front pillar upper trim be sure to set the front mole as shown in figure Outside Q nmm Inside Weatherstrip B5M0673A El 45 EXTERIOR INTERIOR TRIM LOWER INNER TRIM EXTERIOR INTERIOR TRIM 19 Lower Inner Trim A REMOVAL 1 Remove the side sill front cover A 2 Remove the rear seat cushion lt Ref to SE 11 REMOVAL Rear Seat gt then remove side sill rear cover B 3 Remove the center pillar lower trim C r Hook pawl BOO0075 B INSTALLATION Install in the reverse order of removal CAUTION Be sure to securely hook pawis of inner trim panel to body flange El 46 REAR QUARTER TRIM EXTERIOR INTERIOR TRIM 20 Rear Quarter Trim 2 WAGON 1 Remove the rear seat lt Ref to SE 11 REMOV A REMOVAL AL Rear Seat gt 1 SEDAN 2 Remove the side sill rear cover 3 Remove the rear rail trim A 4 Loosen the screws and clips to remove the rear quarter upper trim B 5 Remove the rear skirt trim 6 Loosen the bolts and clips to remove the rear quarter lowe
66. Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the airbag resistor from the test harness L 3 Disconnect the connector AB25 from AB24 LE 4 Disconnect the connectors AB17 and AB18 from the airbag control module Ref to AB 15 Airbag Control Module 5 Connect the connector 11 in the test har ness or 12 to the connector AB18 6 Connect the battery ground cable and turn the ignition switch ON 7 Measure the voltage between connector in the test harness or 12 and the chassis ground Connector amp terminal 31 No 6 Chassis ground 31 No 8 Chassis ground Is the voltage less than 1 V Replacethe airbag Replace the body control module harness with side Ref to AB 15 airbag harness Airbag Control Module AB 77 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS X TROUBLE CODE 66 DIAGNOSIS e Seat belt pretensioner LH circuit is shorted to the power supply e Pretensioner is faulty e Pretensioner harness is faulty e Airbag control module is faulty CAUTION Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensi
67. WASHER SYSTEMS e Intermittent operation inspection 1 Turn the wiper switch to INT 2 Adjust the intermittent control switch to MAX 3 Apply battery voltage to switch terminals 16 and 2 and inspect the voltage of terminals 7 and 2 Measure the voltage from after the second time the wiper stops 12V OV 2 12 V OV 11 5 sec 12 V Non variable type 3 1 sec B6M1465A If operation is not as specified replace the switch WW 8 WIPER BLADE WIPER AND WASHER SYSTEMS 4 Wiper Blade D ASSEMBLY A REMOVAL 1 METAL TYPE While pushing the locking clip A up pull out the 1 Insert the wiper rubber onto the blade so that the blade from arm to arrow direction stopper is in the position shown B6M1570A B INSTALLATION 2 Make sure the wiper rubber is securely fastened 1 Install in the reverse order of removal to the pull stopper A 2 Confirm that the clip is locked securely C DISASSEMBLY 1 METAL TYPE Pull on side A of the wiper rubber stopper and re move the rubber from the blade assembly A B6M1498A A B6M1496A 2 RESIN TYPE Pull the wiper rubber top slightly from the stopper and pull out fully Stopper 7 mos SS WW 9 WIPER BLADE WIPER AND WASHER SYSTEMS 2 RESIN TYPE 1 Insert the wiper rubber through the claw 3 Insert the wiper rubber into
68. and combination meter harness connector termi nal Connector amp terminal F78 No 1 i11 No 11 F78 No 2 i11 No 8 CHECK AMBIENT SENSOR 1 Remove the ambient sensor 2 Check the ambient sensor Ref to IDI 17 INSPECTION Ambient Sensor CHECK OUTSIDE TEMPERATURE INDICA Is the voltage more than 4V Is the resistance less than 10 Go to step 3 Repair the wiring harness Replace the ambi ent sensor Is the ambient sensor OK Go to step 4 Is the outside temperature indi Repair the poor Replace the com TOR cator indicating 25 C 77 F contact of ambient bination meter 1 Connect the combination meter harness sensor harness printed circuit connector connector 2 Connect a resistor 2 2 between the ter minals of ambient sensor harness connector 3 Turn the ignition switch ON and check the outside temperature indicator display IDI 10 ee 7 COMBINATION METER ASSEMBLY INSTRUMENTATION DRIVER INFO 3 Combination Meter Assem B INSTALLATION bly Install in the reverse order of removal CAUTION A REMOVAL e Make sure the electrical connector is con 1 Disconnect the battery ground cable nected securely 2 Set the tilt steering at the lowest position Make sure that each meter operates normally 3 Remove the screws and detach the meter visor e
69. as flannel Recom Perform either the same operation as for the 3 Finish mended wax NITTO KASEI Soft 99 TIRE WAX resin section or process No 18 and subse BLACK or equivalent quent operations in the 3 section depending Polish the waxed area with a clean cloth after 5 on the degree and nature of damage to 10 minutes Deep damage caused by scratching fences etc A dent cannot be repaired but a whitened or swelled part can be removed Pro cess Process name Job contents No Clean damaged area with water Removal of dam m Cut off protruding area if any due to collision using a putty knife Grind the affected area with 100 to 500 sand paper Resin section 4 Finish Same as Process No 3 in the 1 section Perform Process No 12 and subsequent oper ations in the 3 section El 26 FRONT BUMPER EXTERIOR INTERIOR TRIM 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 Pro Cess Process name Job contents No 1 Remove the bumper as required 2 Remove the parts built into bumper as required Bumper Place the bumper on a paint worktable as required It is recom
70. at 276 kPa 2 81 kg cm 40 psi max 25 After the system is fully charged close the low pressure valve 26 Close the valve on the refrigerant source Refrigerant amount Refrigerant 0 6 kg 1 31b 0 7 kg 1 5 Ib HVAC SYSTEM HEATER VENTILATOR AND A C 27 Disconnect the hose from the service port and install the service port cap AC 19 REFRIGERANT LEAK CHECK HVAC SYSTEM HEATER VENTILATOR AND A C 5 Refrigerant Leak Check A INSPECTION 1 Operate the A C system for approx 10 minutes and confirm that the high side pressure shows at least 690 kPa 7 03 kg cm 100 psi Then stop the engine to start the leak test 2 Starting from the connection between the high pressure tube and evaporator check the system for leaks along the high pressure side through the compressor The following items must be checked thoroughly 3 Check the joint and seam between the pressure switch dual switch and receiver dryer 4 Check the connections between the condenser and tubes and welded joints on the condenser The leak tester may detect the oil on the condenser fins as a leak 5 Check the joint between the compressor and hoses 6 Check the machined area of compressor and other joints on the compressor 7 Check the thermal limiter if equipped on the compressor housing 8 Check the compressor shaft seal at the area near the center of compressor clutch pulley Some shaft seals show a sli
71. battery TION Refrigerant Charging Procedure gt 2 Using the refrigerant recovery system discharge refrigerant lt Ref to AC 16 OPERATION Refriger ant Recovery Procedure gt 3 Drain LLC from the radiator lt Ref to CO 25 RE PLACEMENT Engine Coolant gt 4 Remove the bolts securing expansion valve and pipe in engine compartment Release the heater hose clamps in engine compartment to remove the hoses 5 Remove the instrument panel lt Ref to El 42 REMOVAL Instrument Panel Assembly gt 6 Remove the support beam 7 Remove the blower motor unit assembly Ref to AC 22 REMOVAL Blower Motor Unit Assem bly 8 Loosen the bolt and nuts to remove the heater and cooling unit AC 28 EVAPORATOR HVAC SYSTEM HEATER VENTILATOR AND 14 Evaporator A REMOVAL 1 Remove the heater and cooling unit lt Ref to AC 28 REMOVAL Heater and Cooling Unit gt 2 Loosen the screws and clip to remove the evap orator cover CAUTION If the evaporator is replaced add appropriate amount of compressor oil to evaporator lt Ref to AC 21 REPLACEMENT Compressor Oil gt B INSTALLATION Install in the reverse order of removal AC 29 HOSE AND TUBE HVAC SYSTEM HEATER VENTILATOR AND A C 15 Hose and Tube A REMOVAL CAUTION e When disconnecting connecting hoses do not apply excessive force to them Confirm that no torsion and excessive tension exists after installing
72. e HFC 134a compressor oil is very hygroscopic When replacing or installing removing A C parts immediately isolate the oil from the atmosphere us ing a plug or tape In order to avoid moisture store the oil in a container with its cap tightly closed 3 REFRIGERANT e The HFC 12 refrigerant cannot be used in the HFC 134a A C system The HFC 134a refrigerant also cannot be used in the HFC 12 A C system e f an incorrect or no refrigerant is used poor lu brication will result and the compressor itself may be damaged 4 HANDLING OF REFRIGERANT e The refrigerant boils at approx 30 C 22 F When handling it be sure to wear safety goggles and protective gloves Direct contact of the refriger ant with skin may cause frostbite If the refrigerant gets into your eye avoid rubbing your eyes with your hands Wash your eye with plenty of water and receive medical treatment from an eye doctor Do not heat a service can If a service can is di rectly heated or put into boiling water the inside pressure will become extremely high This may cause the can to explode If a service can must be warmed up use hot water in 40 C 104 F max e Do not drop or impact a service can Observe the precautions and operation procedure described on the refrigerant can e When the engine is running do not open the high pressure valve of the manifold gauge The high pressure gas will back flow resulting in an ex plosion of the can
73. e Seal the disconnected hose with a plug or vi nyl tape to prevent contamination from enter ing 1 Disconnect the ground terminal from battery 2 Using the refrigerant recovery system discharge refrigerant Ref to AC 16 OPERATION Refriger ant Recovery Procedure 3 Remove the evaporator unit mounting bolt A 4 Remove the low pressure hose attaching bolts B 5 Disconnect the low pressure hose from evapora tor unit 6 Disconnect the low pressure hose from com pressor 7 Remove the low pressure hose from the vehicle 8 Remove the high pressure hose attaching bolts C 9 Disconnect the high pressure hose from com pressor 10 Disconnect the high pressure hose from con denser 11 Remove the high pressure hose from the vehi cle 12 Remove the high pressure tube attaching bolt D 13 Remove the high pressure tube from the vehi cle B INSTALLATION CAUTION e When disconnecting connecting hoses do not apply an excessive force to them Confirm that no torsion and excessive tension exists af ter installing Seal the disconnected hose with a plug or vi tape to prevent contamination from enter ing 1 Install in the reverse order of removal 2 Charge refrigerant lt Ref to AC 17 OPERA TION Refrigerant Charging Procedure gt C INSPECTION NOTE If cracking damage or swelling is found on a hose replace it with a new one AC 30 RELAY AND FUSE 16 Re
74. following di mensions as a guide line 2 3 0 079 0 118 6 0 236 Unit mm in CAUTION e If crimp of rear glass is higher than neces sary glass may get caught in weatherstrip of center pillar corner resulting in early wear of weatherstrip Be careful when adjusting e After adjustment move glass up and down to check whether it is caught GW 21 REAR REGULATOR AND MOTOR ASSEMBLY GLASS WINDOWS MIRRORS 8 Rear Regulator and Motor As sembly A REMOVAL 1 Remove the door glass lt Ref to GW 20 RE MOVAL Rear Door Glass gt 2 Remove the front sash 3 Disconnect the motor connector 4 Loosen four bolts and two nuts to remove regu lator assembly B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the rear door glass lt Ref to GW 21 AD JUSTMENT Rear Door Glass gt C INSPECTION 1 Make sure that the power window motor rotates properly when the battery voltage is applied to the terminals of motor connector 2 Change the polarity of battery connections to the terminals to ensure that the motor rotates in re verse direction GW 22 WINDSHIELD GLASS 9 Windshield Glass A REMOVAL 1 USING WINDSHIELD KNIFE 1 Remove the cowl panel lt Ref to El 33 RE MOVAL Cowl Panel gt 2 Remove the glass molding 3 Tape the body side of the circumference of wind shield glass for protection 4 Apply the sufficient amount of soapy water to
75. keyless entry control module lt Ref to SL 49 Keyless Entry Control Module gt The transmitter cannot be pro 1 Check the transmitter battery and function lt Ref to SL 16 CHECK TRANSMIT TER BATTERY AND FUNCTION INSPECTION Keyless Entry Sys tem gt 2 Check the ignition switch circuit lt Ref to SL 17 CHECK IGNITION SWITCH CIRCUIT INSPECTION Keyless Entry System gt 3 Check the door switch lt Ref to SL 18 CHECK DOOR SWITCH INSPECTION Keyless Entry System gt 4 Replace the keyless entry control module lt Ref to SL 49 Keyless Entry Control Module gt 1 Check the transmitter battery and function lt Ref to SL 16 CHECK TRANSMIT TER BATTERY AND FUNCTION INSPECTION Keyless Entry Sys tem Ref to SL 19 CHECK KEY WARN ING SWITCH INSPECTION Keyless Entry System 3 Check the door switch Ref to SL 18 CHECK DOOR SWITCH INSPECTION Keyless Entry System 4 Check the output signal to integrated module Ref to SL 20 CHECK OUTPUT SIGNAL TO INTEGRATED MOD ULE INSPECTION Keyless Entry grammed The door lock or unlock does not operate NOTE If the door lock control system does not operate when using the door lock switch check the door lock control system Hef to SL 9 INSPECTION Door Lock Control System 2 Check the key warning switch System 5 Replace the keyless entry control module Ref to SL 49 Keyless Entry C
76. lid release handle 2 18 1 84 13 3 4 Trunk lid lock ASSY 8 Rear gate latch T3 25 2 5 18 1 SL 3 GENERAL DESCRIPTION SECURITY AND LOCKS 3 HOOD LOCK AND REMOTE OPENERS cO HOOD END 4 5 V WAGON 3 v CB UD RS 3 5 SEDAN BO0244 1 Hood lock ASSY 5 Pull handle ASSY Tightening torque N m kgf m ft lb 2 Lever ASSY T1 6 4 0 65 4 7 3 Cable T2 32 3 3 23 9 4 Cover SL 4 GENERAL DESCRIPTION SECURITY AND LOCKS 4 KEYLESS ENTRY SYSTEM 1 Keyless entry control module 3 Door switch 2 Rear gate latch switch Wagon 4 Integrated module SL 5 GENERAL DESCRIPTION SECURITY AND LOCKS 5 SECURITY SYSTEM NO Security horn Security control module O nation meter B CAUTION Before disassembling or reassembling the parts always disconnect the battery ground cable When repairing the radio control module etc which are provided with memory functions record the memory contents before disconnecting battery ground cable Otherwise these contents are cancelled upon disconnection Reassemble the parts in the reverse order of disassembly procedure unless otherwise indicated e Adjust the parts to the specifications contained in this manual if so designated Connect the connectors and hoses securely during reassembly After reassembly ensure the functional parts operate smoothly The airbag system w
77. light assembly lt Ref to LI 18 WAGON REMOVAL Rear Combi nation Light Assembly gt 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description gt 3 If NG replace the bulb with a new one 1 20 REAR TURN SIGNAL LIGHT BULB 19 Rear Turn Signal Light Bulb A REMOVAL 1 SEDAN 1 Remove the trunk side trim of rear portion 2 Turn the socket and remove the bulb 2 WAGON 1 Remove the rear combination light assembly Ref to Ll 18 WAGON REMOVAL Rear Combi nation Light Assembly 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to Ll 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one LI 21 LIGHTING SYSTEM REAR SIDE MARKER LIGHT BULB LIGHTING SYSTEM 20 Rear Side Marker Light Bulb A REMOVAL 1 Remove the rear combination light assembly Ref to LI 18 WAGON REMOVAL Rear Combi nation Light Assembly 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to
78. lock arm A 2 With the lock arm A pushed in move the slide lock B in the direction of the arrow B5M1153A 3 With the slide lock B pulled remove the lock arm A to its original position and then pull in the direction of the arrow and separate the connector CAUTION When pulling be sure to hold onto the connec tor and not the wire 2 How to connect Holding the connector and push it in carefully until a connecting sound Is heard CAUTION Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked AB 8 AIRBAG CONNECTOR AIRBAG SYSTEM 3 FRONT SUB SENSOR SIDE AIRBAG SENSOR 1 How to disconnect 1 Holding the outer part A pull it in the direc tion of the arrow CAUTION When pulling be sure to hold onto the connec tor and not the wire 2 How to connect Holding the connector and push it in carefully until a connecting sound is heard CAUTION e Outer A moves back and so do not put your hand on the outer part e Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked 4 PRETENSIONER 1 How to disconnect 1 Move the slide lock A in the direction of the arrow 2 Pull the connector B in the direction of the arrow with slide lock A moved CAUTION When pulling be sure to hold onto the connec tor and not the wire 2 How to connect H
79. or frayed Seat belt is abnormally wound or extended 6 INNER BELT WAGON Check for the following and replace with new parts if necessary e Inner belt is deformed or damaged e Seat belt buckle is engaged improperly SB 13 REAR SEAT BELT SEAT BELT SYSTEM SB 14 LIGHTING SYSTEM Page 1 General Description PE A 2 2 Headlight and Tail Light System 3 35 FrontFog Light 4 4 Signal and Hazard Light System 5 5 Backup LUoht System D Stop Light SySIOIT 7 iu ERR HA UU RRU anaes 8 Combination Switch Light 9 Headlight ASSOmbly vais a n 10 Headight e AEAEE ea 11 Front Tum Signal Light Bulb aen 13 12 Clearance Parking Light Bulb eere tr err tr Pied Fas annue ees 14 13 Front Fog Eight ASSOmbDI ceto i TD RE RES UE 15 14 Front FOG Light Bulb uoi BRE a tut ee 16 15 Front Side Marker Light 17 16 Rear Combination Light Assembly eese 18 17 Gion
80. pil lar lower trim Pull back the floor mat Remove the clip holding the cable 3 Remove the bolt Remove the opener pull han dle Pull handle ASSY 4 Remove the cable from the opener pull handle 5 Remove the striker from the trunk lid 6 Remove the cable from the striker 3 FUEL FLAP OPENER 1 Remove the rear seat lt Ref to SE 11 REMOV AL Rear Seat gt 2 Remove the center pillar lower trim and side sill cover on the passenger side Remove the rear pil lar lower trim Pull back the floor mat Remove the clip holding the cable 3 Remove the bolt Remove the opener pull han dle dB Pull handle p 2 E G5M0151 4 Remove the cable from the opener pull handle 5 Remove the right rear quarter trim lt Ref to El 47 REMOVAL Rear Quarter Trim gt 6 Rotate the fuel lock inside the quarter panel to the left and remove B INSTALLATION 1 HOOD OPENER Install in the reverse order of removal 2 TRUNK LID OPENER Install in the reverse order of removal 3 FUEL FLAP OPENER Install in the reverse order of removal C INSPECTION Make sure the fuel flap opens and closes smoothly SL 42 IGNITION KEY LOCK SECURITY AND LOCKS 20 lgnition Key Lock A REPLACEMENT 1 Disconnect the ground terminal from battery 2 Remove the steering column Ref to PS 23 REMOVAL Tilt Steering Column 3 Secure the steering column in a vise Remove the bolt with a
81. pretensioner NO GOOD AB 3 GENERAL DESCRIPTION AIRBAG SYSTEM Do not allow water or oil to come in contact with e install the wire harness securely with the speci the connector terminals Do not touch the connec fied clips to avoid interference or tangled up with tor terminals other parts NO GOOD G5M0298 The airbag module driver passenger and side When painting or performing sheet metal work and pretensioner must not be disassembled on the front part of the vehicle including the front wheel apron front fender and front side frame re NS BOOR move the front sub sensors and wire harness of the airbag system e When painting or performing sheet metal work on the side of the vehicle including the side sill center pillar and front and rear doors remove the side airbag sensors and wire harness of the airbag system G5M0299 If any damage opening or rust is found on the airbag system wire harness do not attempt to re pair using soldering equipment Be sure to replace the faulty harness with a new genuine part NO GOOD G5M0310 NO GOOD AB 4 GENERAL DESCRIPTION AIRBAG SYSTEM a n M s Bc ut Do not drop the airbag modulator parts subject them to high temperature over 93 C 199 F or let water oil or grease get on them otherwise the in
82. procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL e For detailed concerning diagnostic trouble codes refer to the LIST OF DIAGNOSTIC TROU BLE CODE Ref to CC 26 LIST OF DIAGNOSTIC TROUBLE CODE DTC gt CC 10 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS eee 6 Diagnostics Chart with Symptom A SYMPTOM CHART Repair area Reference Cruise control main switch is 1 Check power supply lt Ref to CC 14 CHECK POWER SUPPLY Diagnostics not turned ON Chart with Symptom gt 2 Check cruise control main Ref to CC 16 CHECK CRUISE CONTROL MAIN switch SWITCH Diagnostics Chart with Symptom 1 Check SET COAST Ref to CC 18 CHECK CRUISE CONTROL COM switch MAND SWITCH Diagnostics Chart with Symptom 2 Check stop light switch Ref to CC 20 CHECK STOP LIGHT SWITCH AND and brake switch BRAKE SWITCH Diagnostics Chart with Symptom 3 Check clutch switch MT Ref to CC 22 CHECK CLUTCH SWITCH MT Diag nostics Chart with Symptom Cruise control cannot be set 4 Check inhibitor switch Ret to CC 24 CHECK INHIBITOR SWITCH AT AT Diagnostics Chart with Symptom 5 Check vehicle speed sen Ref to CC 30 DTC 22 VEHICLE SPEED SENSOR SOr Diagnostics Chart with Diagnostic Trouble Code gt 6 Check motor drive sys lt Ref to CC 34 DTC 35 AND 36 ACTUATOR MOTOR tem Diagnostics Chart with Diagnostic Trouble Code gt
83. side of seat rail A REMOVAL 1 Disconnect the ground terminal from battery 2 While pressing the headrest lock button remove 9 Disconnect the side airbag connector under the the headrest dE seat Side airbag equipped vehicle 10 Disconnect the connector of seat belt warning H5M0704 3 Tilt forward the backrest 4 Move the seat to full front end 5 Remove the bolt cover at rear end of slide rail 11 Remove the front seat from vehicle CAUTION When removing the seat from vehicle take care not to damage body seat or trim B INSTALLATION Install in the reverse order of removal CAUTION Confirm that the seat can move smoothly and be locked securely at any position 7 Move the seat to full rear end SE 6 FRONT SEAT SEATS C DISASSEMBLY 6 Turn the cover and remove the two bolts from hinge 1 DRIVER S SEAT 1 Remove the seat from the vehicle Ref to SE 6 REMOVAL Front Seat 2 Remove the reclining hinge cover 8 Remove the hog rings and then remove seat back rest cover Without side airbag model SE 7 FRONT SEAT SEATS With side airbag model 3 Turn the cover and remove the two bolts from hinge Hog ring 9 Remove the hog rings and then remove the seat cushion cover 4 Remove the hinge screw cover and screw and Standard type model remove seat back rest from hinge Sporty type model 9 Hog ring 2 PASSENGER S
84. switch Check the harness 1 Disconnect the keyless entry control module circuit is OK for open circuits harness connector and shorts 2 Turn the ignition switch ON between the key 3 Measure the voltage between the harness less entry control connector terminal and chassis ground module and igni Connector amp terminal tion relay B176 No 14 chassis ground SL 17 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 7 CHECK DOOR SWITCH Check Yes CHECK DOOR SWITCH CIRCUIT Is the voltage O V when each Go to step 2 Go to step 3 Measure the voltage between the keyless entry door rear gate and trunk lid is control module harness connector terminal opened and chassis ground Connector amp terminal Front and rear door B176 No 7 chassis ground Hear gate or trunk lid B176 No 6 chassis ground CHECK DOOR SWITCH CIRCUIT Is the voltage approx 10 V The door switch is Go to step 3 Measure the voltage between the keyless entry when each door rear gate and OK control module harness connector terminal trunk lid is closed and chassis ground Connector amp terminal Front and rear door B176 No 7 chassis ground Rear gate or trunk lid B176 No 6 chassis ground CHECK DOOR SWITCH 1 Disconnect the door switch harness connec tor 2 Measure the resistance between the door switch terminals Terminal Front LH No 1 No 3 Front RH No 1 No 3
85. the adhesive layer 5 Insert the windshield knife into the adhesive lay er 6 While holding the knife edge and windshield glass edge at a right angle move the windshield knife in parallel to the windshield glass edge along face and edge of windshield glass to cut the adhe sive layer CAUTION e Do not twist windshield knife e Cutting of adhesive layer shall be started with wider gap between windshield glass and body Putty knife Putty knife 4 a AL Putty knife Protective tape Sea Windshield Matching pin Matching GLASS WINDOWS MIRRORS NOTE Because the matching pins are bonded to the cor ners of glass use piano wire to cut the pin Matching pin 2 USING PIANO WIRE 1 Remove the cowl panel lt Ref to El 33 RE MOVAL Cowl Panel gt 2 Remove the roof molding and upper front mold ing 3 Tape the body side of the circumference of wind shield glass for protection 4 Make a hole in the adhesive layer using drill or knife 5 Pass the piano wire through the hole and attach securely both the wire ends to pieces of wood pi G5M0494 6 Pull the wire ends alternately to cut off the adhe sive layer CAUTION Do not tightly pull the piano wire against the windshield glass edge e Be careful not to damage interior and exterior parts e When removal is made with area close to in strument panel place a protection plate over it Pay particular attention to the remova
86. the claw A 4m BOO20C 2 Insert the wiper rubber top until it protrudes E INSPECTION about 20mm 0 79 in from the stopper D 1 When the wiper does not perform well inspect the following e Make sure the movable part of the blade assem bly moves smoothly e Make sure the wiper rubber is not deformed or damaged 2 Replace with a new part if damage is found E 20mm 0 79 in EE I a PETRUS e WW 10 WASHER TANK AND MOTOR WIPER AND WASHER SYSTEMS 5 Washer Tank and Motor D ASSEMBLY 1 Assemble in the reverse order of disassembly A REMOVAL 2 Confirm that water does not leak from installation 1 Open the hood area of motor 2 Disconnect the ground terminal from battery 3 a E INSPECTION 3 Remove the two bolts hose and connector and then remove the tank Apply battery voltage to the connector terminal of the washer motor and make sure the motor oper ates B INSTALLATION Install in the reverse order of removal C DISASSEMBLY Pull out the washer motor from tank WW 11 FRONT WIPER ARM WIPER AND WASHER SYSTEMS 6 Front Wiper Arm C ADJUSTMENT Operate the wiper once Align the wiper blade to A REMOVAL ceramic print point mark A of front window pane 1 Open the hood 2 Remove the cap 3 Loosen the nut to remove arm B6M1193A XA a U INSTALLATION 1 Install in the reverse order
87. the harness and washer hose from the rear gate B5M0733A EXTERIOR BODY PANELS 10 Using a support support the rear gate while re moving gas stay mounting bolts CAUTION When the rear gate is released it may hit and damage the body To prevent this place a shop cloth between body and gate 11 Loosen the rear gate bolts to remove the rear gate EB 19 REAR GATE PANEL EXTERIOR BODY PANELS 2 GAS STAY 1 Open the rear gate Using a support jack to sup port the rear gate CAUTION e After gas stay is removed rear gate cannot stay open Supporting the rear gate with a jack remove the bolts Do not damage piston rods and oil seals e Never disassemble cylinders They contain gas 2 Loosen the bolts to remove gas stay from rear gate B INSTALLATION 1 REAR GATE PANEL 1 Install in the reverse order of removal 2 Install the rear gate panel with uniform clearance to the body Refer to COMPONENT of General Description for tightening torque lt Ref to EB 8 REAR GATE PANEL General Description gt CAUTION Do not damage painted surfaces of body and rear gate 2 GAS STAY 1 Install mounting bolt A to the rear gate panel and body Tightening torque 14 N m 1 8 kgf m 13 ft lb 2 Firmly install the gas stay B to mounting bolt A CAUTION After supporting rear gate with a jack start op eration EB 20 REAR GATE PANEL EXTERIOR B
88. the side airbag sensor RH Ref to AB 16 Side Airbag Sensor S TROUBLE CODE 54 DIAGNOSIS e Side airbag sensor LH is faulty When Code 54 is displayed the circuit within the side airbag sensor LH is faulty Replace the side airbag sensor LH Ref to AB 16 Side Airbag Sensor AB 69 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS T TROUBLE CODE 55 This code is displayed when the side airbag is deployed When this code is displayed the memory cannot be erased Replace the following parts e Airbag control module Ref to AB 15 Airbag Control Module Front seat assembly with side airbag module Operating side Ref to SE 6 Front Seat e Side airbag sensor Operating side Ref to AB 16 Side Airbag Sensor AB 70 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS AB 71 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS U TROUBLE CODE 61 DIAGNOSIS e Seat belt pretensioner RH circuit is open shorted or shorted to ground e Airbag control module is faulty e Pretensioner is faulty e Pretensioner harness is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect
89. then open the center trunk through lid 3 Lift the rear seat backrest and then remove it SE 11 REAR SEAT SEATS B INSTALLATION 2 Remove the hog rings from around the seat backrest 1 WAGON Install in the reverse order of removal 2 SEDAN 1 Hook and fasten the upper back side of the rear seat backrest to the body hook 3 Remove the hog rings on front side of cushion pad and then remove the cover 2 Tighten the bolts 4 Remove the hog rings from around the seat cushion P udi B5M081 1 3 Hook and fasten the seat cushion to the hook on the lower part of the rear seat backrest 9 Hog ring BOO178 5 Remove the hog rings and then remove the cov er C DISASSEMBLY 1 WAGON 1 Remove the rear seat Ref to SE 11 WAG ON REMOVAL Rear Seat Q Hog ring BOO0361 SE 12 REAR SEAT SEATS 2 SEDAN D ASSEMBLY 1 Remove the rear seat lt Ref to SE 11 SEDAN REMOVAL Rear Seat gt 2 Remove the hog rings from around the seat Assemble in the reverse order of disassembly backrest NOTE 0 Hog ring BOO0180 3 Remove the hog rings and then remove the seat cover Q Hog ring BOO0182 4 Remove the hog rings around the seat cushion 5 Remove the hog rings and then remove the seat cover Q Hog ring BO0362 Do not contaminate or damage the cover e While installing the hog rings prevent the seat f
90. 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 be cause problem occurs in the cruise control sys tem or its associated circuits 2 Monitor the signal conditions from switches and sensors tions Code No they are shown on the Subaru CRUISE CONTROL SYSTEM DIAGNOSTICS 2 CRUISE CANCEL CONDITIONS DIAG NOSIS 1 Prepare Subaru Select Monitor kit 2 Connect the diagnosis cable to the Subaru Se lect Monitor 3 Insert the cartridge into the Subaru Select Moni tor Ref to CC 3 SPECIAL TOOLS PREPARATION TOOL General Description S2M0286A 4 Connect the Subaru Select Monitor to the data link connector 1 Data link connector located in the lower por tion of the instrument panel on the driver s side 2 Connect the diagnosis cable to the data link connector CC 9 SUBARU SELECT MONITOR CRUISE CONTROL SYSTEM DIAGNOSTICS 5 Start the engine and turn the cruise control main switch to ON 6 Turn the Subaru Select Monitor switch to ON Power switch S2M0288A 7 On the Main Menu display screen select the All System Diagnosis and press the YES key NOTE The diagnostic trouble code is also shown in the Each System Check mode This mode is called on the Cruise Control Diagnosis screen by se lecting the item Cancel Code s Display 8
91. with Trouble Code A TROUBLE CODE 11 DIAGNOSIS e Airbag main harness circuit is open shorted or shorted to ground e Airbag module harness Driver circuit is open shorted or shorted to ground e Roll connector circuit is open shorted or shorted to ground e Driver s airbag module is faulty e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE STEERING ROLL CONNECTOR E INFLATOR DRIVER SIDE YELLOW YELLOW YELLOW 31218 alol 77 1819 lhoniehahahisheh7 112 rte re 20 2 22 23124 25 26127 28 B5M1098 AB 36 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS CHECK DRIVER S AIRBAG MODULE Does the airbag warning light 1 Turn the ignition switch OFF disconnect the operate properly battery ground terminal and wait more than 20 seconds 2 Remove the driver s airpag module Ref to AB 12 Driver s Airbag Module 3 Conne
92. 1 INSPECTION Keyless Transmitter CHECK LED OF TRANSMITTER 1 Press the LOCK ARM or UNLOCK DISARM button six times to synchronize with the key less entry control module 2 Press the LOCK ARM button CHECK LED OF TRANSMITTER Keep the LOCK ARM button pressed CHECK LED OF TRANSMITTER Press the UNLOCK DISARM button CHECK LED OF TRANSMITTER Keep the UNLOCK DISARM button pressed 3 CHECK HORN CHIRP SETTING CHECK HORN CHIRP SETTING Check the current setting of the horn chirp 1 Remove the key from the ignition switch 2 Close all doors and the rear gate or trunk lid 3 Press the LOCK ARM or UNLOCK DISARM button CHECK HORN CHIRP SETTING 1 Press the UNLOCK DISARM button once 2 Press both the LOCK ARM and UNLOCK DISARM button for more than 2 seconds 3 Press the LOCK ARM or UNLOCK DISARM button Is the voltage more than 2 V Yes Go to step 2 Replace the trans iE mitter battery Go to step 3 Replace the trans mitter Ref to SL 51 REPLACE MENT Keyless Transmitter Go to step 4 Replace the trans mitter Ref to SL 51 REPLACE MENT Keyless Transmitter Go to step 5 Replace the trans mitter Ref to SL 51 REPLACE MENT Keyless Transmitter Does the LED blink two times transmitter is Replace the trans mitter lt Ref to SL 51 REPLACE MENT Keyless Transmitter gt Does the LED blink one time Does the LED blink one time and then turn on
93. 1 No 3 Chassis ground CHECK FUSE No 11 IN JOINT BOX 1 Confirm that the ignition switch is turned OFF 2 Remove the fuse No 11 in joint box and perform visual inspection s the resistance less than 10 to step 3 2 Replace the body harness with air bag main harness s the resistance more than 1 to step 4 AQ Replace the body ness with air ig main harness s fuse No 11 blown Replace fuse No 11 If fuse No 11 lows again repair he body harness Repair the body rness AB 47 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS I TROUBLE CODE 25 DIAGNOSIS e Airbag control module is faulty e Airbag main harness circuit is open Fuse No 6 in joint box is blown Body harness circuit is open CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE 5 lt jfe
94. 1 AA090 Without printer 2 GENERAL TOOLS TOOL NAME REMARKS Used for measuring resistance vollage and ampere CC 3 GENERAL DESCRIPTION CRUISE CONTROL SYSTEM DIAGNOSTICS C INSPECTION 1 BATTERY Measure the battery voltage and specific gravity of electrolyte Standard voltage 12 V or more Specific gravity Above 1 260 2 CRUISE CONTROL CABLE F Cruise control cable 27 7 po 7 BSNS S6M0099A Check the cruise control cable installation If NG install the cable securely 3 ACCELERATOR CABLE NS Se Accelerator 4 ASSY AT mi 2 Cruise control cable LEY SSS S6M0099A 5 CABLE FREE PLAY lt Reduces clearance by 1 9 0 04 in B6M0241A Check that the throttle cam to lever clearance is within specifications Throttle cam to lever clearance 0 1 mm 0 0 04 in If NG adjust the clearance with the adjust nut NOTE Check that the cap is positioned in the groove Check movement of the accelerator cable when the cruise control throttle is moved by hand If NG check the throttle cam 4 THROTTLE CAM Check that the throttle cam moves smoothly If NG repair the throttle cam CC 4 ELECTRICAL COMPONENTS LOCATION CRUISE CONTROL SYSTEM DIAGNOSTICS 3 Electrical Components Location A LOCATION i SES 1 5 BO0322 1 Actuator 4 Cruise contro
95. 17 from the airbag control module lt Ref to AB 15 Airbag Control Module gt 5 Connect the connector 11 in the test har ness or I2 to the connector AB17 6 Disconnect the connector AB23 from the side airbag sensor LH and connect the con nector 1G in the test harness G to the con nector AB23 7 Measure the resistance between connector 31 in the test harness or 2 and connector pes 3G in the test harness G Connector amp terminal 31 No 5 3G No 4 31 No 14 3G No 5 31 No 15 3G No 1 3I No 16 3G No 2 CHECK SIDE AIRBAG HARNESS RH Measure the resistance between connector 31 in the test harness or I2 and the chassis ground Connector amp terminal 31 No 5 Chassis ground 31 No 14 Chassis ground 31 No 15 Chassis ground 31 No 16 Chassis ground Replace the body harness with side airbag harness Is the resistance more than 1 MQ Replace the side Replace the body airbag sensor harness with side LH Ref to AB airbag harness 16 Side Airbag Sensor gt When the sensor replacement is not OK replace the airbag control module lt Ref to AB 15 Airbag Control Module gt R TROUBLE CODE 53 DIAGNOSIS e Side airbag sensor RH is faulty When Code 53 is displayed the circuit within the side airbag sensor RH is faulty Replace
96. 2002 IMPREZA SERVICE MANUAL BODY SECTION This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD QUICK REFERENCE INDEX HVAC SYSTEM HEATER VENTILATOR AND A C AIRBAG SYSTEM AB AIRBAG SYSTEM DIAGNOSTICS AB B SEAT BELT SYSTEM S LIGHTING SYSTEM WIPER AND WASHER SYSTEMS ENTERTAINMENT COMMUNICATION SYSTEM GLASS WINDOWS MIRRORS GW BODY STRUCTURE BS INSTRUMENTATION DRIVER INFO IDI SEATS SECURITY AND LOCKS EXTERIOR INTERIOR TRIM EXTERIOR BODY PANELS CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM DIAGNOSTICS OPTION PARTS G1830BE6 e HVAC SYSTEM HEATER VENTILATOR AND A C 1 2 3 4 6 f 8 9 General
97. 22 Security Control Module A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the console cover C Hook pawl 3 Disconnect the connector from the security con trol module 4 Remove bolt A and loosen bolt B NOTE Loosen bolt B without completely removing it S6M0482A 5 Remove the security control module B INSTALLATION Install in the reverse order of removal NOTE To install the security control module tighten the bolts securely so that the bolts do not come loose C INSPECTION 1 IMPACT SENSITIVITY TEST 1 Remove the key from the ignition switch 2 Close all windows 3 Close all doors and the rear gate or trunk lid 4 Cover the hood with a blanket 5 Press the LOCK ARM button of the transmitter 6 Confirm that the security indicator light blinks ev ery 2 seconds 7 Hit the center of the windshield with your palm and make sure the alarm operates Center of windshield Hit with palm B6M1424A If NG adjust the impact sensitivity Ref to SL 45 ADJUSTMENT Security Control Module D ADJUSTMENT 1 IMPACT SENSITIVITY NOTE Before adjustment make sure the security control module has been securely installed on the bracket 1 Remove the security control module lt Ref to SL 45 REMOVAL Security Control Module 2 Adjust the sensitivity adjust screw in the security control module NOTE After adjusting be sure to plug the adjust
98. 3 Drive the vehicle faster than 10 km h 6 MPH 4 Measure voltage between transmission con trol module harness connector terminal and chassis ground CAUTION To measure the voltage and or resistance use 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 Connector amp terminal Turbo model B56 No 17 Chassis ground Non turbo model B55 No 13 Chassis ground Repair harness connector between cruise control module and transmission control module Is the voltage less than 1 V lt more than 4 V Replace cruise control module lt Ref to CC 5 Cruise Control Module gt Replace transmis sion control mod ule lt Ref to AT 45 Transmission Control Module TCM gt CC 32 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS C DTC 28 WIRING HARNESS OPENED CHECK BATTERY Is battery specific gravity more Go to step 2 Charge or replace Measure battery specific gravity of electrolyte than 1 250 battery Go to step 2 CHECK FUSES CONNECTORS AND HAR 15 there anything unusual Repair or replace End of inspection NESSES about the appearance of main faulty parts Check the condition of the main and other fuse fuse harness connector fuses and harnesses and connectors Also and grounding check for pro
99. 4 Compressor bracket upper T3 23 0 2 35 17 0 5 Compressor T4 28 9 2 95 21 3 6 Compressor bracket lower T5 35 3 6 26 AC 8 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 6 HEATER DUCT HV0056 1 Front defroster nozzle 4 Side ventilation duct LH 7 Rear heater duct RH 2 Side defroster duct LH 5 Side ventilation duct RH 3 Side defroster duct RH 6 Rear heater duct LH AC 9 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C C CAUTION 1 HFC 134A A C SYSTEM e Unlike the old conventional HFC 12 system com ponents the cooling system components for the HFC 134a system such as the refrigerant and com pressor oil are incompatible e Vehicles with the HFC 134a system can be iden tified by the label A attached to the vehicle Before maintenance check which A C system is in stalled in the vehicle a 4 1817 2 COMPRESSOR OIL e HFC 134a compressor oil has no compatibility with that for R12 system e Use only the manufacturer authorized compres sor oil for the HFC 134a system only use DH PR Do not mix multiple compressor oils If HFC 12 compressor oil is used in a HFC 134a A C system the compressor may become stuck due to poor lubrication or the refrigerant may leak due to swelling of rubber parts On the other hand if HFC 134a compressor oil is used in a HFC 12 A C system the durability of the A C system will be lowered
100. 5MO0663B AB 17 FRONT SUB SENSOR AIRBAG SYSTEM 10 Front Sub Sensor A REMOVAL 1 Turn the ignition switch OFF 2 Disconnect the ground cable from the battery and wait for at least 20 seconds before starting work 3 Remove the front bumper lt Ref to El 23 RE MOVAL Front Bumper gt 4 Loosen the two bolts to remove sensor cover 5 Remove the bolt and then detach the front sub sensor 6 Disconnect the connector from the front sub sen Sor Oe B INSTALLATION Install in the reverse order of removal C INSPECTION Check for the following and replace the damaged parts with new parts e Front sub sensor mounting bracket and con nector are damaged RE0020 AB 18 AIRBAG SYSTEM DIAGNOSTICS ON 0 9T Basic Diagnostic Procedure CHECK List TOLTPEOTVIO Wii asa Secr aes a ebur us Der General DeSscrptlOr i oov Fel eue do tui ou EE nue tonos bark Electrical Components Location ccccccscecececeesesseseeeeeseneneeeesenenseeseees 18 Control Module I O Signal esee 20 PUG Conneclor o 21 Airbag Warning Light Illumination 23 Read Diagnostic Trouble 24 INSPECTION Modessa TO 25 Clear Memory Fu Ue Ve DURER RR CK
101. 6 ACTUATOR MOTOR tem Diagnostics Chart with Diagnostic Trouble Code gt 3 Check motor clutch drive Ref to CC 36 DTC 37 ACTUATOR MOTOR CLUTCH Diagnostics Chart with Diagnostic Trouble Code gt CC 12 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS CC 13 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS B CHECK POWER SUPPLY TROUBLE SYMPTOM Cruise control can be set normally but indicator does not come on When main switch is pressed WIRING DIAGRAM B RY IGNITION SWITCH F B No 18 U CRUISE CONTROL MAIN SWITCH CRUISE CONTROL MODULE Iom 1 gt lt 2 1 2 3 4 5 6 7 10 tt 12 13 14 15 16 17 18 19 20 0287 CC 14 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS CHECK POWER SUPPLY Is the voltage more than 10 V iGo to step 2 Check fuse No 1 Disconnect cruise control module harness 18 in fuse amp relay connector box 2 Turn ignition switch ON Check harness 3 Measure voltage between harness connec for open or short tor terminal and chassis ground between cruise Connector amp terminal control module B94 No 12 Chassis ground and fuse amp relay Dox CHECK GROUND CIRCUIT Is the resistance less than 10 Power supply and Repair harness Measure resistance between harness connec ground circuit are tor terminal and chassis ground OK Connector amp te
102. 81 No 1 Chassis ground B281 No 2 Chassis ground CHECK GROUND CIRCUIT Is the resistance less than 10 The power supply Repair the har Measure the resistance between the harness 0 and ground circuit ness connector terminal and chassis ground Connector amp terminal B281 No 4 13 Chassis ground 4 CHECK DOOR LOCK SWITCH AND CIRCUIT check Ye No _ CHECK DOOR LOCK SWITCH CIRCUIT Is the resistance less than 10 Go to step 2 Go to step 3 1 Disconnect the integrated module harness connector 2 Measure the resistance between the har ness connector terminal and chassis ground when moving the door lock switch to LOCK Connector amp terminal Driver side B280 No 12 Chassis ground Passenger side B280 No 12 Chassis ground CHECK DOOR LOCK SWITCH CIRCUIT Is the resistance less than 10 Go to step 3 The door lock Measure the resistance between the harness 0 switch is OK connector terminal and chassis ground when the door lock switch is moved to UNLOCK Connector amp terminal Driver side B280 No 11 Chassis ground Passenger side B280 No 11 Chassis ground CHECK DOOR LOCK SWITCH 1 Disconnect the door lock switch harness connector 2 Measure the resistance between the door lock switch terminals when moving the door lock switch to LOCK Terminal Driver side No 5 No 9 Passenger side No 5 No 4 CHECK DOOR LOCK SWITCH Is the
103. AGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS F TROUBLE CODE 22 This code is indicated when the front airbag and the pretensioner are in operation Once this code is indicated memory is not erasable therefore replace the following parts e Airbag control module lt Ref to AB 15 Airbag Control Module gt e Driver s airbag module Ref to AB 12 Driver s Airbag Module e Passenger s airbag module Ref to AB 13 Passenger s Airbag Module e Front sub sensor of both sides Ref to AB 18 Front Sub Sensor e Front seat belt outer with pretensioner of both sides Ref to SB 8 Front Seat Belt gt G TROUBLE CODE 23 DIAGNOSIS AB6 AB17 and AB18 are not connected properly to airbag control module CAUTION Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work Check Yes CHECK POOR CONTACT IN CONECTORS Check if the rust or damage Replace the airbag Go to step 2 AB6 AB17 and AB18 appear on the harness con control module 1 Turn the ignition switch OFF disconnect the nector and the control module lt Ref to AB 15 battery ground terminal and wait more than 20 connector Airbag Control seconds Module Replace 2 Disconnect the connectors AB6 AB17 the body harness and AB18 from the airbag control module with airbag main Ref to AB 15 Airbag Co
104. AT BELT SEAT BELT SYSTEM 5 Rear Seat Belt 7 Remove the two bolts and adjustable anchor AS SY A REMOVAL 1 OUTER BELT SIDE SEDAN 1 Remove the rear seat lt Ref to SE 11 REMOV AL Rear Seat gt 2 Remove the side sill rear lower cover lt Ref to El 46 REMOVAL Lower Inner Trim gt 3 Remove the seat belt lower anchor bolt 2 OUTER BELT CENTER SEDAN 1 Remove the rear seat lt Ref to SE 11 REMOV AL Rear Seat gt 2 Remove the seat belt lower anchor bolt 4 Remove the anchor cover Remove the bolt and shoulder anchor from pillar rH REO0011 3 Remove the quarter pillar trim Ref to El 47 Removal Rear Quarter Trim 4 Remove the rear shelf trim Ref to El 53 RE MOVAL Rear Shelf Trim 5 Remove the bolts and then detach the seat belt 5 Remove the quarter pillar trim Ref to El 47 REMOVAL Rear Quarter Trim 6 Remove the bolts and then detach the seat belt SB 10 REAR SEAT BELT SEAT BELT SYSTEM 3 INNER BELT SEDAN 1 Remove the rear cushion lt Ref to SE 11 RE MOVAL Rear Seat gt 2 Remove the bolts and then detach the inner inks belt O ee 4 OUTER BELT SIDE WAGON 1 Remove the luggage floor mat Ref to El 56 REMOVAL Luggage Floor Mat 2 Remove the rear seat Ref to SE 11 REMOV AL Rear Seat 3 Remove the side sill rear lower cover Ref to El 46 REMOVAL Lower Inner Trim
105. B176 No 2 Chassis ground CHECK HARNESS BETWEEN KEYLESS EN 15 the resistance less than 10 Replace the inte TRY CONTROL MODULE AND INTEGRAT grated module ED MODULE 1 Disconnect the keyless entry control module harness connector and integrated module har ness connector 2 Measure the resistance between the keyless entry control module harness connector termi nal and integrated module harness conector terminal Connector amp terminal B176 No 9 B280 No 14 B176 No 2 B280 No 13 SL 20 Check the room light circuit Check the harness for open circuits and or shorts between the inte grated module and room light Replace the key less entry control module Replace the key less entry control module Check the harness for open circuit or shorts between the keyless entry control module and integrated module SECURITY SYSTEM SECURITY AND LOCKS 4 Security System A SCHEMATIC lt Ref to WI 121 SCHEMATIC Security System gt B ELECTRICAL SPECIFICATION B6M0972 Content Measuring condition i AGNI Ignition switch ON 2 INPUT Battery voltage is present when ignition switch is turned ON Passive arm MNA ea SE NN 4 Trunk room light switch Sedan INPUT V is present when trunk room light switch or rear gate latch switch is rear gate latch switch Wagon turned ON Door switch 5 INPUT V is present when any door is open Empty
106. B18 from the airbag control module lt Ref to AB 15 Airbag Control Module gt 5 Connect the connector 11 in the test har ness or I2 to the connector AB17 6 Measure the resistance between connector 31 in the test harness or I2 and the connec tor 3L in the test harness L Connector amp terminal 3I No 11 3L No 6 31 No 13 31 No 5 CHECK SIDE AIRBAG HARNESS LH Measure the resistance of the connector 3l in the test harness or 12 Connector amp terminal 31 No 11 No 13 CHECK SIDE AIRBAG HARNESS LH Measure the resistance between the connector 31 in the test harness or 12 and the chassis ground Connector amp terminal 31 No 11 Chassis ground 31 No 13 Chassis around ao to step 2 s the resistance less than 10 2 20 to step 3 Replace the body 3arness with side airbag harness Is the resistance more than 1 MO Replace the body arness with side airbag harness 3o to step 4 s the resistance more than 1 3eplacethe airbag Replace the body MQ ontrol module with side Ref to AB 15 airbag harness Airbag Control Module AB 75 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS W TROUBLE CODE 65 DIAGNOSIS Seat belt pretensioner RH circuit i
107. C 16 OPERATION Refriger ant Recovery Procedure gt 2 Disconnect the ground terminal from battery 3 Disconnect the pressure hose and pipe from condenser 5 Remove two bolts While lifting condenser pull it out through space between the radiator and the ra diator panel CAUTION Be careful not to damage the condenser fins If a damaged fin is found repair it using a thin screwdriver If the condenser is replaced add appropriate amount of compressor oil to the compressor lt Ref to AC 21 REPLACEMENT Compressor Oil gt HVAC SYSTEM HEATER VENTILATOR AND A C B INSTALLATION 1 Install in the reverse order of removal CAUTION Replace the O rings on hoses or pipes with new ones and then apply compressor oil Confirm that lower guide of condenser A has been fit ted into holes on radiator panel B4M1822A 2 Charge refrigerant lt Ref to AC 17 OPERA TION Refrigerant Charging Procedure gt C INSPECTION 1 Confirm that no dust or insects are found on the condenser fins Air blow or flush fins with water as needed 2 Confirm that no oil leaks from condenser If a fail ure is found replace the condenser with a new one AC 27 HEATER AND COOLING UNIT HVAC SYSTEM HEATER VENTILATOR AND A C 13 Heater and Cooling Unit B INSTALLATION 1 Install in the reverse order of removal A REMOVAL 2 Charge refrigerant lt Ref to AC 17 OPERA 1 Disconnect the ground terminal from
108. Center pillar upper trim 7 Hook 10 Front garnish 3 Rear pillar upper trim 8 Rear skirt trim 11 Rear garnish 4 Rear rail trim 9 Side sill rear cover 12 Front garnish 5 Rear pillar lower trim 10 Center pillar lower trim 13 Rear garnish El 14 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 17 ROOF TRIM SEDAN 1 Roof trim 18 ROOF TRIM WAGON 1 Roof trim 2 Roof trim sun roof model 3 Sun roof garnish El 15 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 19 LUGGAGE FLOOR MAT 1 Front floor mat 3 Side floor mat RH b Side floor mat LH 2 Floor box 4 Center floor mat El 16 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 20 INNER ACCESSORIES BO0256 1 Hook 2 Sun visor 3 Assist grip B PREPARATION TOOL TOOL NAME REMARKS Used for removal of rim El 17 FRONT GRILLE EXTERIOR INTERIOR TRIM 2 Front Grille A REMOVAL 1 Open the hood 2 Remove the four clips B INSTALLATION Install in the reverse order of removal El 18 HOOD GRILLE 3 Hood Grille A REMOVAL 1 Remove the four clips of hood insulator 2 Remove seven bolts and clip A to remove the hood duct 4 Remove three white clips and two black clips to remove the hood grille El 19 EXTERIOR INTERIOR TRIM HOOD GRILLE EXTERIOR INTERIOR TRIM B INSTALLATION BO0375 A White clip B Black clip C Bolt 1 Replace the black clip 1
109. D A C Use the oil specified in the service manual to lu bricate the O rings Apply the oil to the top and sides of the O rings be fore installation Apply the oil to the area including the O rings and tube beads e After tightening use a clean shop towel to re move excess oil from the connections and any oil which may have run on the vehicle body or other parts f any leakage is suspected after tightening do not retighten the connections Disconnect the con nections remove the O rings and check the O rings threads and connections AC 11 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C D PREPARATION TOOL CAUTION When working on vehicles with the HFC 134a system only use HFC 134a specified tools and parts Do not mix with CFC 12 tools and parts If HFC 134a and CFC 12 refrigerant or compres sor oil is mixed poor lubrication will result and the compressor itself may be destroyed Tools and Equipment Wrench In order to help prevent mixing HFC 134a and CFC 12 parts and liquid the tool and screw type and the type of service valves used are dif ferent The gas leak detectors for the HFC 134a and CFC 12 systems must also not be inter changed enc Tool amp screw type Valve type Quick joint type Description Various WRENCHES will be required to service any A C system A 7 to 40 N m 0 7 to 4 1 kg m 5 to ft lb torque wrench with various
110. DULE INSPEC TION Combination Meter System Ref to IDI 8 CHECK FUEL LEVEL SEN SOR INSPECTION Combination Meter System Ref to IDI 9 CHECK ENGINE COOLANT TEMPERATURE SEN SOR INSPECTION Combination Meter System Ref to IDI 10 CHECK OUTSIDE TEMPERA TURE INDICATOR INSPECTION Combi nation Meter System MUS APER i UIN Ee IT prc AT gt E z LEME ETRE ATE EES CUN EF TS EY d E TM Le erga SNR RETA COMBINATION METER SYSTEM INSTRUMENTATION DRIVER INFO CHECK POWER SUPPLY FOR COMBINA TION METER 1 Remove the combination meter Ref to IDI 11 REMOVAL Combination Meter Assem bly gt 2 Disconnect the combination meter harness connector 3 Turn the ignition switch to ON 4 Measure the voltage between the combina tion meter connector 110 and chassis ground Connector amp terminal 110 No 7 Chassis ground CHECK POWER SUPPLY FOR COMBINA TION METER Measure the voltage between the combination meter connector 110 and chassis ground Connector amp terminal 110 No 10 Chassis ground CHECK GROUND CIRCUIT OF COMBINA TION METER 1 Turn the ignition switch to OFF 2 Measure the resistance of harness between the combination meter connector 110 and chassis ground Connector amp terminal 110 No 6 Chassis ground 2 CHECK POWER SUPPLY AND GROUND CIRCUIT
111. Drive vehicle at least 30 km h 19 MPH with cruise speed set 9 If the cruise speed is canceled itself without do ing any cancel operations a diagnostic trouble code will appear on select monitor display _ CAUTION e A diagnostic trouble code will also appear when cruise cancel is effected by driver Do not confuse Have a co worker ride in vehicle to assist in diagnosis during driving NOTE Diagnostic trouble code will be cleared by turning ignition switch or cruise control main switch to OFF 3 REAL TIME DIAGNOSIS 1 Connect the select monitor 2 Turn the ignition switch and cruise control main switch to ON 3 Turn the Subaru Select Monitor switch to ON 4 On the Main Menu display screen select the Each System Check and press the YES key 5 On the System Selection Menu display screen select the Cruise Control and press the YES key 6 Press the YES key after displayed the informa tion of engine type 7 On the Cruise Control Diagnosis display screen select the Current Data Display amp Save and press the YES key 8 Make sure that normal indication is displayed when controls are operated as indicated below Depress release the brake pedal Stop light switch and brake switch turn ON e Turn ON the SET COAST switch Turn ON the RESUME ACCEL switch e Depress release the clutch pedal MT Set the selector lever to P or N AT NOTE e For detailed operation
112. ECK FRONT SUB SENSOR HARNESS Isthe resistance less than 10 Go to step 8 Replace the body harness with front sub sensor har ness RH RH 1 Connect the connector 2F in the test har ness F to the connector AB15 2 Measure the resistance between connector 3H in the test harness and connector in the test harness F Connector amp terminal 3F No 5 3H No 5 3F No 6 3H No 6 CHECK FRONT SUB SENSOR HARNESS RH Measure the resistance between connector 3H in the test harness H and connector 3F in the test harness F Connector amp terminal 3F No 6 3H No 6 3F No 5 3H No 5 CHECK FRONT SUB SENSOR HARNESS RH Measure the resistance between connector in the test harness F and the chassis ground Connector amp terminal 3F No 5 Chassis ground 3F No 6 Chassis ground CHECK FRONT SUB SENSOR RH 1 Connect the connector 2H in test harness H to the front sub sensor RH 2 Measure the resistance of the connector 3H in the test harness H Connector amp terminal 3H No 3 No 4 11 CHECK FRONT SUB SENSOR RH Measure the resistance between connector 3H in the test harness H and the chassis ground Connector amp terminal 3H No 3 Chassis ground 3H No 4 Chassis ground Is the resistance more than 1M Go to step 9 Replace the body harness with front sub sensor har
113. ECURITY AND LOCKS 4 CHECK FUSE CHECK FUSE Is the fuse blown 15 A and Remove and visually check the fuse No 2 and 20 A 7 in main fuse box 5 CHECK POWER SUPPLY AND GROUND CIRCUIT CHECK POWER SUPPLY 1 Disconnect the security control module har ness connector 2 Measure the voltage between the harness connector terminal and chassis ground Connector amp terminal B93 No 11 chassis ground CHECK POWER SUPPLY 1 Disconnect the security control module har ness connector 2 Measure the voltage between the harness connector terminal and chassis ground Connector amp terminal B93 No 13 chassis ground CHECK GROUND CIRCUIT Replace the fuse with a new one Is the voltage more than 10 V to step 2 Is the voltage more than 10 V Go to step 3 Is the resistance less than 10 The power supply Measure the resistance between the harness Q connector terminal and chassis ground Connector amp terminal B93 No 14 chassis ground 6 CHECK DOOR SWITCH CHECK DOOR SWITCH CIRCUIT Measure the voltage between the security con trol module harness connector terminal and chassis ground Connector amp terminal Front and rear door B93 No 5 4 chassis ground Rear gate or trunk lid B93 No 4 chassis ground CHECK DOOR SWITCH CIRCUIT Measure the voltage between the security con trol module harness connector terminal and chassis ground Conne
114. EM T RE0057 Inner seat belt LH Tightening torque N m kgf m ft Ib Case center ELR T 30 3 1 22 Anchor cover Adjustable anchor ASSY SB 3 GENERAL DESCRIPTION SEAT BELT SYSTEM 3 REAR SEAT BELT WAGON RE0058 1 Outer seat belt RH b Inner seat belt LH Tightening torque kgf m ft lb 2 Outer seat belt CENTER 6 Anchor cover T 30 3 1 22 3 Outer seat belt LH 7 Adjustable anchor ASSY 4 Inner seat belt RH SB 4 GENERAL DESCRIPTION SEAT BELT SYSTEM B CAUTION e Before starting turn the ignition switch OFF dis connect the battery ground cable and wait for 20 seconds or more e The pretension system has a backup power source The pretensioner might deploy if you do not wait for 20 seconds or more before starting work e Do not drop or apply any impact to the preten sioner e f oil grease or water gets on the pretensioner wipe it off immediately with a dry cloth e Do not expose the pretensioner to high tempera ture or flame e Do not allow current to flow through or voltage to reach the pretensioner Do not use a circuit tester to check resistance of the pretensioner Do not disassemble or attempt to repair the pre tensioner If it is dented cracked or deformed re place it with a new one e Do not use the airbag or pretensioner parts from other vehicles Always replace the parts with new parts e When handling a seat belt with a deployed pre tensioner w
115. FLATS He HE0044 AB 14 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS o o x lt I r o H e x lt gt tr 2 O H Q e LU tea gt EN Z lt ke ep EE a resistance of air 3 a D o gt C 3 qj c D 2 2 N g QU LLI Z c lt F T LL o o cR M ME 3 3 bag control module 100 Q 7 8j9 jtojt aft 2 RE0046 AB 15 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS AIRBAG RESISTOR ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299PA040 AIRBAG RESISTOR Used in replacement of airbag module which resistance value is same as airbag module 0047 2 DAN 6 5 REO048 AB 16 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS AB 17 ELECTRICAL COMPONENTS LOCATION AIRBAG SYSTEM DIAGNOSTICS 4 Electrical Components Location A LOCATION cp em MID AB8 483 Ic 16 17 D 7 8 11 12 RE0049 Male connector me 2 2 3 2 2 2 2 Color Yellow Yellow Yellow Yellow Yellow Yellow Yelow Yelow Blue Biue Yelow Blue me 2 2 i 2 2 2 2 2 2 2
116. HART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Check Yes CHECK SIDE AIRBAG MODULE Does the airbag warning light Replace the front 1 Turn the ignition switch OFF disconnect the operate properly seat with side air battery ground terminal and wait more than 20 bag module LH seconds lt Ref to SE 6 2 Disconnect the connector AB21 from the Front Seat gt seat belt pretensioner LH lt Ref to SB 8 Front Seat Belt gt 3 Disconnect the connector AB20 from AB19 and connect the connector 1F in the test harness F to AB19 4 Connect the airbag resistor to the connector SF in the test harness F 5 Connect the battery ground terminal and turn the ignition switch ON CHECK SIDE AIRBAG HARNESS LH 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 Go to step 2 Is the voltage less than 1 V Replacethe airbag Replace the body control module harness with side Het to AB 15 airbag harness seconds Airbag Control 2 Disconnect the airbag resistor from the test Module harness F 3 Disconnect the connector AB17 from the ans airbag control module lt Ref to AB 15 Airbag Control Module gt 4 Connect the connector 11 in the test har ness or 12 to the connector AB17 5 Connect the battery ground terminal and turn the ignition switch ON 6 Measure the voltage between connect
117. Harness and or connector is cracked deformed or open Lead wire is exposed e Mounting bracket is cracked or deformed 3 AIRBAG MODULE SIDE Check for the following and replace damaged parts with new parts e Front seat is damaged or deformed e Harness and or connector is cracked deformed or open Lead wire is exposed 4 AIRBAG CONTROL MODULE Check for the following and replace the damaged parts with new parts Control module is cracked or deformed e Mounting bracket is cracked or deformed e Connector is scratched or deformed e Airbag is deployed e Side airbag is deployed 5 FRONT SUB SENSOR If the front section of vehicle as shown in the figure is damaged 24 AN NS NS AN SS SS SS NUUD SN NS zs G5M031 1 Check for the following and replace the damaged parts with new parts e Front sub sensor is cracked or deformed e Mounting bracket is cracked or deformed Connector is scratched or cracked Airbag is deployed 6 FRONT SUB SENSOR HARNESS Check for the following and replace the damaged parts with new parts e Harness is open lead wire is exposed and cor rugated tube is noticeably cracked e Connector is scratched or cracked AB 10 INSPECTION LOCATIONS AFTER A COLLISION AIRBAG SYSTEM 7 SIDE AIRBAG SENSOR If the side section of vehicle as shown in the figure is damaged Check for the following and replace the damaged parts with n
118. ION Measure the horn switch resistance 514 is pushed 1 and Body When horn switch ground B INSTALLATION Install in the reverse order of removal COM 5 HORN SWITCH COMMUNICATION SYSTEM COM 6 GLASS WINDOWS MIRRORS 1 General Description eeeeenenm enne 2 2 Power Window nnnm 9 3 Rear Window Defogger 11 4 Remote Control Mirror Hm 13 b Front DOOF GlaSS cesis d a 15 6 Front Regulator and Motor Assembly 19 7 Rear DOOM GIASS e Ip I VR EET Y ea TR eee orate 20 8 Rear Regulator and Motor 22 9 Windshield Glass acce erri ER regt 23 10 FREER Gata Glas S oo ie eb o v en pti evi ees 26 ti Rear Quarter GIB888 ciii abaci aera dairy ar wagers 27 12 Rear Window GIASS saca ER Sed a 28 13 Inner Rearview M ITOr eene eene nre nene nenne nn nnne nean a nnn 29 14 Power Window Control Switch eee mh 30 15 Rear Window nnns 16 Outer Mirror en
119. K DOOR SWITCH INSPECTION Security System Security indica Check the security indicator light Ref to SL 25 CHECK SECURITY tor light circuit INDICATOR LIGHT CIRCUIT INSPECTION Security System Ref to SL 26 CHECK SECURITY Clearance light The security system can be set but the security indicator light or clearance light does not blink Security indica tor light Check the security indicator light circuit Clearance light Check the clearance light opera tion The security system does not alarm when one of Check the door switch the door is opened The security alarm does not activate Check the security horn HORN INSPECTION Security Sys tem Ret to SL 27 CHECK CLEAR ANCE LIGHT OPERATION INSPECTION Security System Starter motor Check the interrupt relay circuit Ref to SL 27 CHECK INTER deactivation RUPT RELAY CIRCUIT INSPEC TION Security System Ref to SL 16 CHECK TRANS Ignition switch Check the clearance light opera tion Check the transmitter function The security system cannot be canceled MITTER BATTERY AND FUNC TION INSPECTION Keyless Entry System Ref to SL 27 CHECK IGNITION SWITCH CIRCUIT INSPECTION Security System Check the ignition switch circuit SL 23 SECURITY SYSTEM S
120. LH is faulty e Side airbag module LH is faulty e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons e When inspecting the side airbag harness disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE SIDE AIRBAG SENSOR LH INFLATOR SIDE LH T mm 1 2 3 4 B5M1106 AB 60 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Check Yes CHECK SIDE AIRBAG MODULE Does the airbag warning light Replace the front Go to step 2 1 Turn the ignition switch OFF disconnect the operate properly seat with side air battery ground terminal and wait more than 20 bag module LH seconds Ref to SE 6 2 Disconnect the connector AB21 from the Front Seat seat belt pretensioner LH Ref to SB 8 Go to step 3 Replace the body harness with side airbag harness Connector amp terminal Front Seat Beit gt 3 Dis
121. MS 2 REAR WIPER B6M1463B 1 Wiper rubber 7 Spacer B Tightening torque N m kgf m ft Ib 2 Wiper blade ASSY 8 Nut T1 6 0 0 61 4 4 3 Wiper arm 9 Cap T2 7 5 0 76 5 5 4 Wiper motor 10 Wiper arm cover T3 8 0 0 82 5 9 5 Spacer A 6 Cushion WW 3 GENERAL DESCRIPTION WIPER AND WASHER SYSTEMS 3 WASHER TANK BO0295 1 Washer nozzle 5 Front washer motor Tightening torque N m kgf m ft lb 2 Washer hose 6 Rear washer motor T 6 0 0 61 4 4 3 Washer tank 7 Grommet 4 Washer tank cap C CAUTION e Reconnect the connectors and hoses securely After reconnecting confirm that each function operates normally Be careful that the wire harnesses of airbag system pass near electrical parts and switches e Care must be taken when installing the piping hose so that no bending jamming etc are caused e If even alittle oil or grease such as silicon oil gets in the tank and washer passages an oil film easily forms on the glass causing the wiper to chatter and judder Therefore be careful not to let this happen WW 4 WIPER AND WASHER SYSTEM 2 Wiper and Washer System A SCHEMATIC 1 WIPER AND WASHER FRONT lt Ref to WI 127 SCHEMATIC Wiper and Washer System Front gt 2 WIPER AND WASHER REAR lt Ref to WI 128 SCHEMATIC Wiper and Washer System Rear gt WW 5 WIPER AND WASHER SYSTEMS WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEMS B INSPEC
122. No 1 B161 No 6 B94 No 11 B161 No 1 CHECK CRUISE CONTROL MAIN SWITCH 15 cruise control main switch Remove and check cruise control main switch OK lt Ref to CC 6 Cruise Control Main Switch CC 17 CRUISE CONTROL SYSTEM DIAGNOSTICS e Check fuse No 18 in fuse amp relay box e Check harness for open or short between cruise control main switch and fuse amp relay box Hepair harness Replace cruise control module Heplace cruise control main switch DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS D CHECK CRUISE CONTROL COMMAND SWITCH TROUBLE SYMPTOM Cruise control cannot be set Cancelled immediately WIRING DIAGRAM HORN SWITCH CRUISE CONTROL COMMAND SWITCH 9 CANCEL SWITCH HORN RELAY HORN CRUISE CONTROL MODULE 11213 12 jang 31415 5 6 7 8 BOO288 CC 18 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS Ye No 1 CHECK SET COAST SWITCH CIRCUIT Is the voltage 0 V when SET Go to step 2 Go to step 4 1 Disconnect cruise control module harness COAST switch is not pressed connector Is the voltage more than 10 V 2 Turn ignition switch ON when SET COAST switch is 3 Measure voltage between harness connec jpressed Go to step 3 Go to step 4 Cruise control Go to step 4 command switch circuit is OK tor ter
123. O INTEGRATED MOD ULE INSPECTION Keyless Entry System 6 Replace the keyless entry control module Ref to SL 49 Keyless Entry Control Module 1 Check the transmitter battery and function Ref to SL 16 CHECK TRANSMIT TER BATTERY AND FUNCTION INSPECTION Keyless Entry Sys tem Ref to SL 18 CHECK DOOR SWITCH INSPECTION Keyless Entry System Ref to SL 19 CHECK HORN OPERATION INSPECTION Key less Entry System 4 Replace the keyless entry control module Ref to SL 49 Keyless Entry Control Module The horn chirp does not operate 1 Check the horn chirp function 2 Check the transmitter battery and function 3 Check the key warning switch 4 Check the door switch 5 Check the horn operation The room light operation does not activate 2 Check the room light operation 3 Check the key warning switch 4 Check the door switch 5 Check the output signal to integrated module The door warning does not operate 2 Check the door switch 3 Check the horn operation SL 15 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 2 CHECK TRANSMITTER BATTERY AND FUNCTION CHECK TRANSMITTER BATTERY 1 Remove the battery from the transmitter lt Ref to SL 51 REMOVAL Keyless Transmit ter 2 Check the battery voltage Ref to SL 5
124. ODY PANELS DISPOSAL 1 GAS STAY CAUTION Gas is colorless odorless and harmless How ever gas pressure may spray cutting powder or oil Be sure to wear dust resistant goggles 1 Cover with a vinyl sack as shown in the figure Gas stay Vinyl sack CAUTION Prevent the vinyl sack from being caught by drill cutting edge 2 Lift the body side slightly with piston rods fully ex tended and secure the body side on vise stand Drill a hole in 2 to 3 mm 0 08 to 0 12 in diameter at a point 10 to 200 mm 0 39 to 7 87 in from door side and bleed gas stay completely Body side Door side 190mm 10mm 7 48 in 0 39 in Portion to be drilled Piston rod Cylinder EB 21 REAR GATE PANEL EXTERIOR BODY PANELS EB 22 CRUISE CONTROL SYSTEM Te General DESCrIONOM NETTE 2 ACUO eet tei a i 4 3 Cruise Control Module 5 4 Cruise Control Main nennen nennen 6 5 Cruise Control Command Switch esses nennen 7 6 Stop and Brake SWIEGD oia E ni 8 fe WIC I 9 8 HAMIDIOl ci REUTERS 10 GENERAL DESCRIPTION CRUISE CONTROL SYSTEM 1 General Description A COMPONENT BO0322 1 Actuator 4 Cruise control main switch 7 Cruise control module 2 Inhibitor switch AT 5 Clutch switch MT 3 Cru
125. ONTROL SYSTEM DIAGNOSTICS CHECK INHIBITOR SWITCH CIRCUIT 1 Disconnect inhibitor switch harness connec tor 2 Turn ignition switch ON 3 Turn cruise control main switch ON 4 Measure voltage between harness connec tor terminal and chassis ground Connector amp terminal T7 No 12 Chassis ground CHECK INHIBITOR SWITCH CIRCUIT 1 Turn cruise control main switch and ignition switch OFF 2 Disconnect starter motor harness connector 3 Measure resistance between inhibitor switch harness connector terminal and chassis ground Connector amp terminal T7 No 7 B14 No 1 CHECK INHIBITOR SWITCH Remove and check inhibitor switch lt Ref to CC 10 Inhibitor Switch gt Is the resistance less than 10 Is inhibitor switch OK CC 25 Is the voltage more than 10 V Go to step 2 Go to step 3 Inhibitor switch cir cuit is OK Check the follow ing interrupt relay with security sys tem Ref to SL 48 Interrupt Relay Harness for open or short between inhibitor switch and cruise control module Repair harness Replace inhibitor switch LIST OF DIAGNOSTIC TROUBLE CODE DTC CRUISE CONTROL SYSTEM DIAGNOSTICS 7 List of Diagnostic Trouble Code DTC A LIST Dic em 0 Contents of diagnosis Cruise control module inner relay is seized when main Switch is OFF Inner relay is seized M Vehicle speed sensor Cruise control module is ab
126. R UNSERE Y RET SE THU Tem TG KE e mio Ne WT Em UAM PO EF SPEEDOMETER 4 Speedometer A REMOVAL Disassemble the combination meter and then re move the speedometer and tachometer assembly Ref to 1DI 12 DISASSEMBLY Combination Meter Assembly B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the speedometer resistance SIN and SIN 200 8 2 COS and COS 200 8 Q If NG replace the speedometer and tachometer assembly If OK replace the combination meter printed circuit IDI 13 INSTRUMENTATION DRIVER INFO TACHOMETER INSTRUMENTATION DRIVER INFO 5 Tachometer A REMOVAL Disassemble the combination meter and then re move the speedometer and tachometer assembly lt Ref to IDI 12 DISASSEMBLY Combination Meter Assembly gt B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the tachometer resistance COS COS Vy A t_ oi SIN SIN B6M1232A SIN and SIN 200 8 Q COS and COS 200 8 Q If NG replace the speedometer and tachometer assembly If OK replace the combination meter printed circuit IDI 14 FUEL GAUGE 6 Fuel Gauge A REMOVAL Disassemble the combination meter and then re move the water temperature gauge and fuel gauge assembly lt Ref to IDI 12 DISASSEMBLY Com bination Meter Assembly B INSTALLA
127. RBO 126 DTC P0117 ENGINE COOLANT TEMPER ATURE SENSOR CIRCUIT LOW INPUT Diagnostic Procedure with Diagnostic Trouble Code DTC gt CHECK HARNESS BETWEEN ENGINE Is the resistance less than 10 Check the water the wiring COOLANT TEMPERATURE SENSOR AND 0 temperature harness COMBINATION METER gauge Ref to 1 Turn the ignition switch to OFF IDI 16 2 Disconnect the connector from the engine REMOVAL Water coolant temperature sensor and combination Temperature meter Gauge 3 Measure the resistance between the engine coolant temperature sensor harness connector E8 and combination meter harness connec tor i12 Connector amp terminal E8 No 3 112 No 9 IDI 9 COMBINATION METER SYSTEM INSTRUMENTATION DRIVER INFO 8 CHECK OUTSIDE TEMPERATURE INDICATOR Sep eck ves Go to step 2 Replace the com bination meter printed circuit 1 CHECK POWER SUPPLY FOR AMBIENT SENSOR 1 Turn the ignition switch OFF 2 Disconnect the connector from the combina tion meter 3 Turn the ignition switch ON 4 Measure the voltage between the combina tion meter terminal and chassis ground Connector amp terminal i11 No 11 Chassis ground CHECK HARNESS BETWEEN AMBIENT SENSOR AND COMBINATION METER 1 Turn the ignition switch OFF 2 Disconnect the connector from the ambient sensor 3 Measure the resistance between the ambi ent sensor harness connector terminal
128. RONT WASHER NOZZLE 8 Front Washer Nozzle A REMOVAL 1 Remove the washer hose from the washer noz zle 2 Open the clips on the underside of the hood with a thin screwdriver or other tool and remove the washer nozzle EN Be Te a a Meere 7 WIPER AND WASHER SYSTEMS B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the position of the washer liquid sprayer lt Ref to WW 15 ADJUSTMENT Front Washer Nozzle gt C INSPECTION Make sure the nozzle and hose are not clogged Make sure the hose is not bent D ADJUSTMENT 1 Turn the wiper switch to OFF position 2 When the vehicle stops adjust the washer injec tion position as shown in the figure Injection position A 257 mm 10 12 in B 512 mm 20 16 in WW 15 REAR WIPER ARM WIPER AND WASHER SYSTEMS 9 Rear Wiper Arm A REMOVAL 1 Raise the wiper arm cover A 2 Loosen the nut to remove wiper arm B6M1201A B INSTALLATION 1 Install in the reverse order of removal 2 Operate the rear wiper once 3 Align the blade to rear defogger heat wire A C ADJUSTMENT 1 Operate the rear wiper once 2 Align the blade to rear defogger heat wire A WW 16 REAR WIPER MOTOR WIPER AND WASHER SYSTEMS 10 Rear Wiper Motor C INSPECTION 1 Connect the battery to wiper motor connector A REMOVAL and confirm that wiper motor operates 1 Disconnect the ground terminal from battery 2 Remove the
129. Rear LH No 1 No 3 Hear RH No 1 No 3 Rear gate No 1 No 2 Trunk lid No 1 No 2 CHECK DOOR SWITCH Measure the resistance between the door switch terminals Terminal Front LH No 1 No 3 Front RH No 1 No 3 Rear LH No 1 No 3 Rear RH No 1 No 3 Hear gate No 1 No 2 Trunk lid No 1 No 2 Is the resistance more than 1 MQ when the door switch is pushed Go to step 4 Replace the door Switch Check the harness Replace the door for open circuits switch and shorts between the key less entry control module and door switch Is the resistance less than 1 9 when the door switch is released SL 18 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 8 CHECK KEY WARNING SWITCH Yes Replace the fuse with a new one CHECK FUSE Remove and visually check the fuse No 6 in the main fuse box CHECK KEY WARNING SWITCH CIRCUIT 1 Disconnect the keyless entry control module harness connector 2 Insert the key into the ignition switch LOCK position 3 Measure the voltage between the harness connector terminal and chassis ground Connector amp terminal B176 No 16 4 chassis ground CHECK KEY WARNING SWITCH CIRCUIT 1 Remove the key from the ignition switch 2 Measure the voltage between the harness connector terminal and chassis
130. Remove the three bolts and then carefully re move the airbag module 6 Refer to the CAUTION for handling of a re moved airbag module lt Ref to AB 3 CAUTION General Description gt C INSTALLATION Install in the reverse order of removal CAUTION Do not allow harness and connectors to inter fere or get tangled up with other parts D INSPECTION Check for the following and replace the damaged parts with new parts e Airbag module harness connector and mount ing bracket are damaged AB 13 SIDE AIRBAG MODULE AIRBAG SYSTEM 6 Side Airbag Module A CAUTION Refer to the CAUTION of General Description be fore handling the airbag module lt Ref to AB 3 CAUTION General Description gt B REMOVAL CAUTION The side airbag module cannot be detached from the front seat assembly When replacing side airbag module replace front seat assembly Ref to SE 6 REMOVAL Front Seat C INSTALLATION Ref to SE 6 INSTALLATION Front Seat D INSPECTION Check for the following and replace the damaged parts with new parts Front seat is deformed or damaged e Harness and or connector is cracked deformed or open e Lead wire is exposed AB 14 AIRBAG CONTROL MODULE 7 Airbag Control Module A REMOVAL CAUTION Do not disassemble the airbag control mod ule e If the airbag control module is deformed or if water damage is suspected repl
131. S WINDOWS MIRRORS T Rear Door Glass 5 Loosen two screw to remove weather strip outer A REMOVAL 1 Remove the rear door trim Ref to El 38 RE MOVAL Rear Door Trim 2 Remove the sealing cover Ref to EB 17 RE MOVAL Rear Sealing Cover 3 Remove the stabilizer 6 Operate the power window switch to remove glass as shown in the figure and remove two nuts 7 Loosen two rear sash installation nuts and move the rear sash backward 8 Remove the glass CAUTION Avoid impact and damage to the glass GW 20 REAR DOOR GLASS GLASS WINDOWS MIRRORS B INSTALLATION 1 Install in the reverse order of removal CAUTION Make sure that glass stay is placed securely in sash 2 Adjust rear door glass Ref to GW 21 AD JUSTMENT Rear Door Glass C ADJUSTMENT NOTE The rear door glass as a rule should be adjusted in the same manner as front glass although they are different in dimension Special notes for rear glass are given below 1 Adjust the glass position using the following di mensions as a guide line 12 0 472 12 0 472 Unit mm in CAUTION if dimensions are smaller than the given di mensions glass may get caught in weather strip during ifting lowering operation In the worst case it may cause glass not to be opened fully e After adjustment move glass and down to check whether it is caught 2 Adjust the crimp of glass using the
132. STRUMENTATION DRIVER INFO 1 General Description A SPECIFICATIONS Speedometer Electric pulse type Temperature gauge Thermistor cross coil type Fuel gauge Resistance cross coil type Tachometer Tum signal indicator light Charge indicator light Oil pressure indicator light ABS warning light Malfunction indicator light Hi beam indicator light 14V 1 4W Door open warning light Seal belt warring light ED ED ED ED LED LED Brake fluid and parking brake warning LED LED LED LED LED LED Combination meter light FWD dicar ih a AIRBAG warning ig Meter iluminator ig AT OIL TEMP warning ght EDS Security indicator gn Low fuel warning igh 9 AT select lever position indicator light LCD back igh IDI 2 GENERAL DESCRIPTION INSTRUMENTATION DRIVER INFO B CAUTION Be careful not to damage the meters and instrument panel Be careful not to damage the meter glasses Make sure the electrical connector is connected securely After installation make sure that each meter operates normally Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces Do not apply excessive force to the circuit plate Do not drop or otherwise apply impact C PREPARATION TOOL 1 GENERAL TOOLS TOOL NAME REMARKS Used for measuring resistance and vollage IDI 3 l E COMBINATION METER SYSTEM INSTRUMENTATION DRIVER INFO 2 Combinati
133. T SPOT LIGHT LIGHTING SYSTEM 23 Spot Light A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the lens A and spot light mounting screw B 3 Disconnect the harness connectors and remove the spot light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 SPOT LIGHT BULB 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one 2 SPOT LIGHT SWITCH Measure the spot light resistance Switch position Standard L or More than 1M and 15 050 LI 25 ROOM LIGHT LIGHTING SYSTEM 24 Room Light A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the lens A and room light mounting screws B B6M1479A 3 Disconnect the harness connectors and remove the light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 ROOM LIGHT BULB 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one 2 ROOM LIGHT SWITCH Measure the room light resistance B6M1489A Switch postion OFF Morethan iM DOOR LI 26 LUGGAGE ROOM LIGHT LIGHTING SYSTEM 25 Luggage Room Light 2 LUGGAGE ROOM LIGHT SWITCH A REMOVAL Measure the luggage room light res
134. T WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS See O Ye T NS CHECK POWER SUPPLY Is the voltage more than 10 V Go to step 2 Check harness for 1 Turn ignition switch OFF open or short 2 Disconnect harness connector from cruise between cruise Go to step 3 Go to step 4 Replace cruise control actuator Ref to CC 4 Actuator gt Terminals No 3 No 6 control actuator control main CHECK HARNESS BETWEEN ACTUATOR 15 resistance less than 10 Q to step 5 Repair harness AND CRUISE CONTROL MODULE 1 Disconnect harness connector from cruise control module 2 Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal Connector amp terminal B7 No 2 B94 No 13 3 Turn ignition switch ON switch and cruise 4 Turn cruise control main switch ON control actuator 5 Measure voltage between cruise control actuator harness connector terminal and chas sis ground Terminals B7 No 4 Chassis ground CHECK HARNESS BETWEEN ACTUATOR 5 resistance less than 10 Q Replace cruise Repair harness AND CRUISE CONTROL MODULE control module Measure resistance between cruise control Ref to CC 5 module harness connector terminal and cruise Cruise Control control actuator harness connector terminal Module Connector amp terminal B7 No 3 B94 No 14 CHECK GROUND CIRCUIT OF ACT
135. T30 9 Side airbag module T2 10 1 0 7 2 3 Airbag module ASSY Driver 10 Airbag main harness 20 2 0 14 5 4 Airbag module ASSY Passenger 11 Front sub sensor harness T4 25 2 5 18 1 b Airbag control module 12 Front sub sensor 6 TORX bolt T40 13 TORX boit T30 AB 2 GENERAL DESCRIPTION AIRBAG SYSTEM B CAUTION When servicing a vehicle be sure to turn the ig nition switch OFF disconnect the ground terminal from battery and wait for more than 20 seconds before starting work e The airbag system is fitted with a backup power source If the airbag system is serviced within 20 seconds after the ground terminal is disconnected it may inflate e f the sensors airbag module airbag control module pretensioner and harness are deformed or damaged replace them with new genuine parts NO GOOD G5M0291 Do not use the airbag or pretensioner parts from other vehicles Always replace the defective parts with new parts e Never re use a deployed airbag or pretensioner When checking the system be sure to use a dig ital circuit tester Use of an analog circuit tester may cause the air bag to activate erroneously e When checking use a test harness Do not di rectly apply the tester probe to any connector termi nal of the airbag NO GOOD G5M0293 NO GOOD Test harness G5M0294 e Do not check continuity of the driver passenger side airbag modules and
136. TIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Check Yes CHECK SIDE AIRBAG MODULE Does the airbag warning light Replace the front 1 Turn the ignition switch OFF disconnect the operate properly seat with side air battery ground terminal and wait more than 20 bag module RH seconds lt Ref to SE 6 2 Disconnect the connector AB26 from the Front Seat gt seat belt pretensioner RH lt Ref to SB 8 Go to step 3 Replace the body harness with side airbag harness Front Seat Belt gt 3 Disconnect the connector AB25 from Go to step 4 Replace the body harness with side Go to step 5 Replace the body harness with side airbag harness AB24 and connect the connector 1F in the airbag harness Go to step 6 Replace the body test harness F to AB24 4 Connect the airbag resistor to the connector harness with side airbag harness Replace the airbag control module in the test harness F 5 Connect the battery ground terminal and turn the ignition switch ON lt Ref to AB 15 Airbag Control Module gt Go to step 2 CHECK SIDE AIRBAG HARNESS RR Is the resistance less than 10 1 Turn the ignition switch OFF disconnect the Q battery ground terminal and wait more than 20 seconds 2 Disconnect the airbag resistor from the test harness F 3 Disconnect the connector AB18 from the air bag control module Ref to AB 15 Airbag Cont
137. TION Install in the reverse order of removal C INSPECTION Measure the fuel gauge resistance B6M1233A Terminal Resistance IGN and GND 17010 Q IGN and UNIT 354 10 Q UNIT and GND 136 10 Q lf NG replace the water temperature gauge and fuel gauge assembly If OK replace the combination meter printed circuit IDI 15 INSTRUMENTATION DRIVER INFO WATER TEMPERATURE GAUGE INSTRUMENTATION DRIVER INFO 7 Water Temperature Gauge A REMOVAL Disassemble the combination meter and then re move the water temperature gauge and fuel gauge assembly Ref to 101 12 DISASSEMBLY Com bination Meter Assembly gt B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the water temperature gauge resistance B6M1233A If NG replace the water temperature gauge and fuel gauge assembly If OK replace the combination meter printed circuit IDI 16 AMBIENT SENSOR 8 Ambient Sensor A REMOVAL 1 Disconnect the battery ground cable 2 Disconnect the ambient sensor connector 3 Remove ambient sensor A from the radiator lower panel B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the ambient sensor resistance 2200725 77 If NG replace the ambient sensor IDI 17 INSTRUMENTATION DRIVER INFO AMBIENT SENSOR INSTRUMENTATION DRIVER INFO IDI 18 SEATS Page 1 General DESCnDliC
138. TION Wiper and washers do not operate 1 Wiper fuse F B No 14 15 2 Combination switch 3 Wiper motor 4 Wire harness Wipers do not operate in LO or HI 1 Combination switch 2 Wiper motor 3 Wire harness Wipers do not operate in INT 1 Combination switch 2 Wiper motor 3 3 Wire harness Washer motor does not operate 1 Washer switch 2 Washer motor 3 Wire harness Wipers do not operate when washer switch is ON 1 Washer motor 2 Wire harness Washer fluid spray does not operate 1 Washer hose and nozzle WW 6 COMBINATION SWITCH WIPER WIPER AND WASHER SYSTEMS 3 Combination Switch Wiper A REMOVAL 1 Loosen the screw to remove a steering column cover 2 Disconnect the connectors from combination switches 3 Loosen the screw to remove combination switch B INSTALLATION Install in the reverse order of removal C INSPECTION e Measure the combination switch 56 0137 st 1 Ww 7 16 less than 10 INT 7 and 16 less than 1 FRONT LO 7 and 17 less than 12 Hi 8 and 17 less than 1Q less than 10 2 and 10 Washer ON 2 and 12 less than 1Q 10 and 12 OFF more than 1MQ HEAR less than 1Q ON 2am1 _ 2 and 10 2 and 12 10 and 12 Washer ON less than 19 If continuity is not as specified replace the switch WW 7 COMBINATION SWITCH WIPER WIPER AND
139. UATOR Measure resistance between cruise control actuator harness connector terminal and chas sis ground Terminals B7 No 6 Chassis ground MEASURE RESISTANCE OF ACTUATOR CLUTCH Measure resistance of cruise control actuator clutch Is resistance less than 10 Q Repair harness Is resistance approximately 39 Q CC 37 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS F DTC 38 MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY CHECK ACTUATOR MOTOR Are foreign particles caught in Replace cruise Check the cruise 1 Disconnect harness connector from cruise gear or does inner gear control actuator control cable control actuator engage and disengage lt Ref to CC 4 adjustment lt Ref 2 Remove cruise control actuator from mount jimproperly Actuator gt to CC 4 CABLE ing bracket FREE PLAY Gen 3 Pull cable by hand to check for looseness or eral Description gt status of inner gear engagement CC 38 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS G DTC 39 MOTOR IS OVERLOADED CHECK THE OPERATING CURRENT TO 15 current more than 10 Replace cruise Check the power TUATOR MOTOR control module supply circuit 1 Connect Subaru Select Monitor to data link lt Ref to CC 5 Ref to CC 14 connector Cruise Control CHECK POWER 2 Try to drive the vehicle while operating
140. UIT Measure voltage between harness connector terminal and chassis ground Connector amp terminal B65 No 4 Chassis ground e Check harness for open or short between stop light brake switch and cruise control module AT e Check clutch Is the voltage more than 10 V CHECK STOP LIGHT SWITCH AND BRAKE SWITCH CIRCUIT Su 1 Turn cruise control main switch and ignition switch OFF 2 Disconnect cruise control module harness connector 3 Measure resistance between cruise control module harness connector terminal and stop light switch and brake switch harness connec tor terminal Connector amp terminal B94 No 20 B65 No 3 B94 No 16 B65 No 1 CHECK STOP LIGHT SWITCH AND BRAKE SWITCH Remove and check stop light switch and brake Switch Ref to CC 8 Stop and Brake Switch Is the resistance less than 10 2 CC 21 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS F CHECK CLUTCH SWITCH MT TROUBLE SYMPTOM Cruise control cannot be set WIRING DIAGRAM BATTERY SBF 1 SBF 2 F B No 16 O ORO 4 STOP LIGHT SWITCH AND BRAKE SWITCH STOP LIGHT CLUTCH SWITCH MT EE ES da SWITCH AT MODEL lt r MT MODEL CRUISE CONTROL MODULE HA BOO289 CC 22 DIAGNOSTICS CHART WITH SYMPTOM CHECK CLUTCH SWITCH CIRCUIT 1 Disconnect clutch switch ha
141. Using a tram tracking gauge measure all the di mensions e When using a tape measure carefully measure dimensions without letting the tape measure sag or twist e Measure the linear dimensions between cores of holes e Suffixes RH and LH indicate right hand and left hand e Measure at the center of the circle around the outside of the body panel Datum point S Body panel B5M1133A BS 11 BODY STRUCTURE DATUM DIMENSIONS BODY STRUCTURE 1 CENTER STRUCTURE N 2 NN Se Eas ae ETT A 317 485 83 84 59 76 694 208 982 08 onl Ve x NE 6081 82 Wen M 02 20 6 La Pa 0 9 94 86 7 92 Er E HE 80 ies i e 2 1 l i Z S 3 EN EEG CH wit Lape 920 p er eee 5 TiN LE I H G 2 8 yer HE 87 88 wu T 87 CE ___ 5 m aat aa gt Nok E C AA 0 SSS pe um 1 Side sill 2 Upper surface BO0438 BS 12 DUNS NS NIE UNS NT DATUM DIMENSIONS BODY STRUCTURE 2 WAGON SEDAN FRONT STRUCTURE Unit mm in ___Ponttopoint Dimenson Pomtopon 1 188 44 80 1 188 44 80 1 116 43 94 1 116 43 94 2 LH to 3 RH emean 476579 BS 13 DATUM DIMENSIONS BODY STRUCTURE Unit mm in Pointtopo
142. Vacuum 100 9 kPa 757 mmHg 29 8 inHg 100 5 kPa 754 mmHg 29 7 inHg 99 8 kPa 749 mmHg 29 5 inHg 99 2 kPa 744 mmHg 29 3 inHg 98 5 kPa 739 mmHg 29 1 inHg 97 2 kPa 729 mmHg 28 7 inHg 95 8 kPa 719 mmHg 28 3 inHg 18 3 C 65 F 23 9 C 75 F 29 4 C 85 F 35 C 95 F 1 Close the valves on low high pressure sides of the manifold gauge Low pressure gauge Compound pressure gauge High pressure gauge 2 Install the low high pressure hoses to the corre sponding service ports on the vehicie respectively 3 Connect the center hose of the manifold gauge set with the vacuum pump HVAC SYSTEM HEATER VENTILATOR AND A C 4 Carefully open the valves on the low high pres sure sides to activate the vacuum pump Low pressure gauge Compound pressure gauge High pressure gauge Slowly open Vacuum pump Turn ON 5 After the low pressure gauge reaches 100 0 kPa 750 mmHg 29 5 inHg or higher evacuate the system for approx 15 minutes 6 After 15 minutes of evacuation if the reading shows 100 0 kPa 750 mmHg 29 5 inHg or higher close the valves on the both sides to stop the vac uum pump Low pressure gauge Compound pressure High pressure gauge AC 17 REFRIGERANT CHARGING PROCEDURE HVAC SYSTEM HEATER VENTILATOR AND A C 8 Leave it at least 5 minutes and then check the low pressure gauge reading for any changes When a gauge indicator shows near to z
143. ace the airbag control module with a new genuine part Do not drop the airbag control module e After removal keep the airbag control mod ule on a dry clean surface away from moisture heat and dust 1 Turn the ignition switch OFF 2 Disconnect the ground terminal from battery and wait for at least 20 seconds before starting Work 3 Remove the console box Ref to El 41 RE MOVAL Console Box 4 Disconnect the connector from the airbag control module 5 Using T40 TORX bit Tamper resistant type remove the four TORX bolts Ores SI S REO0001 B INSTALLATION CAUTION Use new TORX bolts during re assembly Install in the reverse order of removal C INSPECTION Check for the following and replace the damaged parts with new parts e Control module connector and mounting brack et are damaged e Airbag is deployed e Side airbag is deployed AB 15 AIRBAG SYSTEM SIDE AIRBAG SENSOR AIRBAG SYSTEM 8 Side Airbag Sensor A REMOVAL 1 Turn the ignition switch OFF 2 Disconnect the ground terminal from battery and wait for at least 20 seconds before starting work 3 Remove the outer belt FRONT lt Ref to SB 8 OUTER BELT FRONT REMOVAL Front Seat Belt gt 4 Using T30 TORX bit Tamper resistant type remove the two TORX bolts 5 Detach the side airbag sensor and then discon nect the airbag connector RE0018 B INSTALLATION
144. al is released Stop light switch Then check that e Battery voltage is present when brake pedal is depressed e 0 volt is present when brake pedal is released CC 7 CRUISE CONTROL MODULE I O SIGNAL CRUISE CONTROL SYSTEM DIAGNOSTICS SCHEMATIC 1 CRUISE CONTROL lt Ref to WI 61 SCHEMATIC Cruise Control Sys tem gt CC 8 SUBARU SELECT MONITOR 5 Subaru Select Monitor A OPERATION 1 GENERAL The on board diagnosis function of the cruise con trol system uses an external Subaru Select Moni tor The on board diagnosis function operates in two categories which are used depending on the type of problems 1 Cruise cancel conditions diagnosis 1 This category of diagnosis requires actual vehicle driving in order to determine the cause as when cruise speed is cancelled during driv ing although cruise cancel condition is not en tered 2 Cruise control module memory stores the cancel condition Code No which occurred dur ing driving When there are plural cancel condi pm Select Monitor CAUTION e The cruise control memory stores not only the cruise cancel which occurred although cancel operation is not entered by the driver but also the cancel condition input by the driver e 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
145. ar Door Lock Actuator A REMOVAL 1 Remove the rear door latch assembly lt Ref to SL 34 REMOVAL Rear Door Latch Assembly gt 2 Loosen two screws to remove the rear door lock acutuator B INSTALLATION Install in the reverse order of removal CAUTION Make sure the lock works properly after instal lation C INSPECTION 1 Disconnect the door lock actuator harness con nector 2 Connect the battery to the door lock actuator ter minals Actuator operation No and No 1 Unlocked Locked No 1 and No 3 Locked Unlocked If NG replace the door lock actuator SL 35 REAR GATE OUTER HANDLE SECURITY AND LOCKS 13 Rear Gate Outer Handle A REMOVAL 1 Remove the rear gate trim lt Ref to El 52 RE MOVAL Rear Gate Trim gt 2 Remove the rear gate latch assembly lt Ref to SL 37 REMOVAL Rear Gate Latch Assembly gt 3 Loosen two nuts to remove the rear gate outer handle B INSTALLATION Install in the reverse order of removal INSPECTION 1 Inspect the rod for deformation 2 Make sure the lever and rod move smoothly SL 36 REAR GATE LATCH ASSEMBLY 14 Rear Gate Latch Assembly A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the rear gate trim lt Ref to El 52 RE MOVAL Rear Gate Trim gt 3 Remove the rear gate key cylinder rod clamp 4 Remove the three bolts 5 Disconnect the connectors and then r
146. arrow with slide lock A moved CAUTION When pulling be sure to hold onto the connec tor and not the wire 2 How to connect Holding the connector A and push it in carefully until a connecting sound is heard CAUTION Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked AB 22 AIRBAG WARNING LIGHT ILLUMINATION PATTERN AIRBAG SYSTEM DIAGNOSTICS 7 Airbag Warning Light nation Pattern A INSPECTION Keep the ignition switch ON and confirm that the airbag warning light remains off approximately 6 seconds after being turned on Approx 6 seconds Airbag warning ON light ignition switch ON AB 23 READ DIAGNOSTIC TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS 8 Read Diagnostic Trouble 3 Read trouble code by identifying the way the air Code bag warning light flashes The airbag warning light flashes a code corre A OPERATION sponding 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 1 Turn the ignition switch ON 2 Connect the diagnosis terminal 1 to the diagno sis connector 2 terminal No 1 in the driver s seat lower cover area NOTE List of Diagnostic Trouble Code Ref to AB 32 List of Diagnostic Trouble Code e Airbag Warning Light Failure Ref to AB 27 Airbag Warning Light Failure Flashing code 12
147. ate the hood buffer to adjust lateral height zles 2 Release the clips to remove the hood insulator B5M0750 3 Remove the bolts to disconnect the hood from hinges 4 Remove the hood grille Turbo model lt Ref to El 19 REMOVAL Hood Grille B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the clearance between hood and fender Clearance must be equal at both sides Tightening torque 24 5 N m 2 49 kgf m 18 ft Ib C ADJUSTMENT 1 Use the hinge mounting holes to align the front hood longitudinally and laterally EB 10 FENDER PANEL EXTERIOR BODY PANELS 3 Fender Panel A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the side sill spoilers Ref to El 36 Side Sill Spoiler If fitted 3 Remove the front bumper face Ref to El 23 REMOVAL Front Bumper gt 4 Remove the mud guard Ref to El 32 RE MOVAL Mud Guard 5 Loosen the bolts to remove front fender B INSTALLATION 1 Install in the reverse order of removal 2 When the fender panel is installed the clearance between fender panel and hood or front fender must be equal Tightening torque 7 35 N m 0 75 kgf m 5 4 ft Ib EB 11 FRONT DOOR PANEL EXTERIOR BODY PANELS 4 Front Door Panel A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the front door trim lt Ref to El 37 RE MOVAL Front Door Trim gt 3 Remove the outer
148. body during removal or installation of bumper 1 Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Description for tightening torque Hef to El 5 REAR BUMPER COMPONENT General Descrip tion C REPAIR Refer to front bumper repair Ref to El 23 RE MOVAL Front Bumper El 31 EXTERIOR INTERIOR TRIM MUD GUARD EXTERIOR INTERIOR TRIM 7 Mud Guard A REMOVAL 1 Jack up the vehicle 2 Loosen the screws and clips to remove the mud guard B INSTALLATION Insert the hook into body and tighten it with screw and clip El 32 COWL PANEL 8 Cowl Panel A REMOVAL 1 Open the hood 2 Remove the wiper arm lt Ref to WW 12 RE MOVAL Front Wiper Arm gt 3 Remove the front panel seal ORS N Clip INSTALLATION Install the reverse order of removal EI 33 EXTERIOR INTERIOR TRIM ROOF SPOILER EXTERIOR INTERIOR TRIM 9 Roof Spoiler A REMOVAL 1 Remove the bolt cap then remove the two bolts 2 Detach the roof spoiler B INSTALLATION Install in the reverse order of removal EI 34 REAR SPOILER EXTERIOR INTERIOR TRIM 10 Rear Spoiler A REMOVAL 1 Disconnect the ground terminal from battery 2 Open the trunk lid 3 Remove the electrical connector A of high mounted stop light 4 Loosen the mounting nut of rear spoiler to re move the rear spoiler CAUTION When
149. ch on front door 2 Open any door rear gate or trunk lid Does the security system not alarm when one of the doors is opened Go to symptom 3 Ref to SL 23 SYMPTOM CHART INSPEC TION Security oystem Go to step 5 Go to symptom 4 Ref to SL 23 SYMPTOM CHART INSPEC TION Security System Go to step 6 Go to symptom 5 TION Security System Go to step 7 Replace the secu rity control mod ule Press the Replace the secu UNLOCK DIS rity contro mod ARM button of ule transmitter and finish the diagno Sis CHECK SECURITY ALARM OPERATION Check the security alarm operation Does the security alarm horn clearance light and security indicator light operate And is the starter motor deactivated CHECK SECURITY ALARM CANCEL OPER Does the security alarm horn ATION and clearance light stop And Het to SL 23 Press the UNLOCK DISARM button of trans is the starter motor activated SYMPTOM mitter CHART INSPEC CHECK BATTERY DISCONNECT PROTEC TION Check the battery disconnect protection Ref to SL 22 CHECK BATTERY DISCONNECT PROTECTION INSPECTION Security Sys tem PERFORM IMPACT SENSITIVITY TEST Perform the impact sensitivity test Ref to SL 45 IMPACT SENSITIVITY TEST INSPEC TION Security Control Module Is the battery disconnect pro tection OK Is the impact sensitivity OK
150. ching pin Dam rubber Adhesive Rear quarter glass Molding B INSTALLATION 1 Cut off the nozzle tip as shown in the figure Dam Matching E 10 0 39 pin Adhesive Unit mm in 12 15 0 47 0 59 Molding 2 Install the glass in the same procedure as for windshield the glass lt Ref to GW 24 INSTALLA TION Windshield Glass gt CAUTION e When door is opened closed after glass is bonded always lower door glass and then open close it carefully Move vehicle slowly l Rear gate glass Molding Matching pin Adhesive Rear quarter glass Molding Adhesive Matching pin Molding Rear quarter glass 3 After completion of all work allow vehicle to stand for about 24 hours NOTE For minimum drying time and time the vehicle must be left standing before driving after bonding follow instructions or instruction manual from the adhe sive manufacturer 4 After curing of adhesive pour the water on exter nal surface of vehicle to check that there are no wa ter leaks CAUTION When a vehicle is returned to the user tell him or her that the vehicle should not be subjected to heavy impact for at least three days GW 27 REAR WINDOW GLASS GLASS WINDOWS MIRRORS 12 Rear Window Glass A REMOVAL 1 Disconnect the electrical connectors from the rear defogger terminals 2 Remove the glass in the same procedure as f
151. ck Control System 3 Check the door lock switch and the circuit Ref to SL 10 CHECK DOOR LOCK SWITCH AND CIRCUIT INSPECTION Door Lock Control System 4 Check the door lock actuator and the circuit Ref to SL 11 CHECK DOOR LOCK ACTUATOR AND CIRCUIT INSPECTION Door Lock Control System The driver side or passenger side Check the door lock switch and the circuit Ret to SL 10 CHECK DOOR door lock switch does not operate LOCK SWITCH AND CIRCUIT INSPECTION Door Lock Control System A specific door lock actuator does not Check the door lock actuator and the circuit Ref to SL 11 CHECK DOOR operate LOCK ACTUATOR AND CIRCUIT INSPECTION Door Lock Control System 2 CHECK FUSE CHECK FUSE is the fuse blown 15A Replace the fuse Check the power Remove and visually check the fuse No 2 in with a new one supply and ground the main fuse box and No 3 in the fuse and circuit Ref to relay box POWER SUPPLY AND GROUND CIRCUIT INSPECTION Door Lock Contro System SL 9 DOOR LOCK CONTROL SYSTEM SECURITY AND LOCKS 3 CHECK POWER SUPPLY AND GROUND CIRCUIT CHECK POWER SUPPLY Is the voltage more than 10 V Go to step 2 Check the harness 1 Disconnect the integrated module harness for open circuits or connector shorts between 2 Measure the voltage between the harness the integrated connector terminal and chassis ground module and the Connector amp terminal fuse B2
152. clothes before disassembling the transmitter B INSTALLATION 1 TRANSMITTER BATTERY Install in the reverse order of removal C INSPECTION 1 TRANSMITTER BATTERY Measure the voltage between the battery termi nal and terminal NOTE e Battery discharge occurs during the measure ment Complete the measurement within 5 sec onds e During the battery voltage measurement the voltage falls more than 1 8 volts in 3 seconds peri od 56 0291 Tester tion ee Battery termi Battery termi More than 2 V nal nal If NG replace the battery Use CR2032 or equiva lent D REPLACEMENT 1 TRANSMITTER PROGRAMMING NOTE Perform the programming when the transmitter is replaced and when an additional transmitter is re quired NOTE Finish the operation from step 1 through 4 within 45 seconds 1 Sit on the driver s seat and close all doors rear gate and trunk lid 2 Open the driver s door 3 Close the driver s door 4 Turn the ignition switch from ON to LOCK ten times within 15 seconds NOTE Do not start the engine at this time 5 The horn chirps one time to indicate that the sys tem has entered in the programming mode 6 Open the driver s door 7 Close the driver s door 8 Press any button on the transmitter that you wish to program into the system 9 Horn will chirp two times to indicate that the transmitter has been programmed NOTE An
153. code indicated Go to Diagnos X Goto step 4 DIAGNOSIS tics Chart with Perform cruise cancel conditions diagnosis Trouble Code Ref to CC 9 Subaru Select Monitor CHECK CRUISE CONTROL SET OPERA Can cruise control be set while Go to step 5 Go to symptom 2 TION driving at 40 km h 25 MPH Ref to CC 11 SYMPTOM CHART Diagnos tics Chart with Symptom Is vehicle speed held within set G Go to symptom 3 SYMPTOM CHART Diagnos tics Chart with CHECK RESUME ACCEL OPERATION Does vehicle speed increase Go to step 7 Go to symptom 4 Check RESUME ACCEL operation or return to set speed after lt Ref to CC 11 RESUME ACCEL switch has SYMPTOM been pressed CHART Diagnos tics Chart with Symptom CHECK SET COAST OPERATION Does vehicle speed decrease Go to step 8 Go to symptom 5 Check SET COAST operation after SET COAST switch has Ref to CC 11 been pressed SYMPTOM CHART Diagnos tics Chart with Symptom CHECK CANCEL OPERATION Is cruise control released after Go to step 9 30 to symptom 6 Check CANCEL operation CANCEL switch has been Ref to CC 11 pressed SYMPTOM CHART Diagnos tics Chart with Symptom ERATION brake pedal has been Ref to CC 11 Check cruise control release operation depressed SYMPTOM CHART Diagnos Finish the diag Go to symptom 8 nostics Ref to CC 11 SYMPTOM tics Chart with CHART Diagnos Check cruise control set operation Qo to step 6 speed 3 km h
154. command switch and cruise contro module Is cruise control command switch OK CC 19 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS E CHECK STOP LIGHT SWITCH AND BRAKE SWITCH TROUBLE SYMPTOM Cruise control cannot be set WIRING DIAGRAM F B No 16 yO STOP LIGHT SWITCH AND BRAKE SWITCH STOP LIGHT CLUTCH SWITCH MT SWITCH AT MODEL Cu MT MODEL CRUISE CONTROL MODULE B94 Fet 4 1T2T8 T4 5 e 7 8 9 Too 11 12 13 14 15 16 t7 16 19 20 BO0289 CC 20 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS Sw T Ye a o 1 CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 V Go to step 2 e Check fuse No switch and the cir SWITCH CIRCUIT 16 in fuse amp relay 1 Disconnect stop light switch and brake switch box Go to step 3 cuit MT Repair harness harness connector e Check harness Are stop light switch and brake Stop light switch Replace stop light 2 Turn ignition switch ON for open or short 3 Turn cruise control main switch ON between stop light switch OK and brake switch switch and brake circuit are OK Switch 4 Measure voltage between harness connec brake switch and tor terminal and chassis ground fuse amp relay box Connector amp terminal B65 No 2 Chassis ground CHECK STOP LIGHT SWITCH AND BRAKE SWITCH CIRC
155. connect the connector AB20 from AB19 and connect the connector 1F in the test harness F to AB19 5 Connect the battery ground terminal and turn the ignition switch ON CHECK SIDE AIRBAG HARNESS LH Is the resistance less than 10 1 Turn the ignition switch OFF disconnect the Q 2 Disconnect the airbag resistor from the test harness F 3 Disconnect the connector AB17 from the Zar airbag control module Ref to AB 15 Airbag Is the resistance more than 1 Go to step 4 Replace the body MQ harness with side airbag harness 31 No 10 No 12 CHECK SIDE AIRBAG HARNESS LH Is the resistance more than 1 Go to step 5 Replace the body Measure the resistance of the connector MQ harness with side in the test harness F airbag harness Connector amp terminal 3F No 3 No 4 CHECK SIDE AIRBAG HARNESS LH is the resistance more than 1 Go to step 6 Replace the body Measure the resistance between connector MO harness with side airbag harness Connector amp terminal 3F No 3 Chassis ground 3F No 4 Chassis ground CHECK SIDE AIRBAG HARNESS LH Is the resistance more than 1 _ Replace the airbag Replace the body ground Airbag Control Connector amp terminal Module 31 No 10 Chassis ground 31 No 12 Chassis ground 4 Connect the connector 11 in the test har ness l or I2 to the connector AB17 5 Measure the resistance between
156. connector 31 in the test harness or 12 and connector 3F in the test harness F Connector amp terminal 3l No 10 3F No 3 31 No 12 3F No 4 CHECK SIDE AIRBAG HARNESS LH Measure the resistance of the connector 3l in the test harness or 12 4 Connect the airbag resistor to the connector battery ground terminal and wait more than 20 Control Module 3F in the test harness F and the chassis Measure the resistance between connector MQ control module harness with side in the test harness F seconds ground 31 in the test harness or I2 and the chassis lt Ref to AB 15 airbag harness AB 61 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS N TROUBLE CODE 45 DIAGNOSIS e Side airbag harness RH is shorted to power supply e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons e When inspecting the side airbag harness disconne
157. control actuator Is resistance approximately 5 Q motor lt Ref to CC 4 Terminals Actuator gt oe No 4 No 1 No 4 No 2 No 4 No 5 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Q AND CRUISE CONTROL MODULE 1 Disconnect harness connector from cruise control module 2 Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal Connector amp terminal B7 No 1 B94 No 7 CHECK HARNESS BETWEEN ACTUATOR AND CRUISE CONTROL MODULE Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal Connector amp terminal B7 No 5 B94 No 5 Go to step 5 Repair harness Replace cruise Repair harness control module Ret to CC 5 Cruise Control Module Is resistance less than 10 Q CC 35 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS E DTC 37 ACTUATOR MOTOR CLUTCH DIAGNOSIS Open or poor contact of cruise control actuator motor clutch TROUBLE SYMPTOM Cruise control cannot be set Cancelled immediately WIRING DIAGRAM IGNITION BATTERY SWITCH F B No 18 CRUISE CONTROL MAIN SWITCH 3 pm CRUISE CONTROL ACTUATOR CRUISE CONTROL MODULE BO0292 CC 36 DIAGNOSTICS CHAR
158. control module Ref to AB 15 Airbag Control Module 4 Connect the connector 11 in the test har ness or I2 to the connector AB18 5 Connect the battery ground terminal and turn the ignition switch ON 6 Measure the voltage between connector 3l in the test harness or 12 and the chassis ground Connector amp terminal 31 No 7 Chassis ground 31 No 9 Chassis ground AB 63 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS O TROUBLE CODE 46 DIAGNOSIS e Side airbag harness LH is shorted to power supply e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons When inspecting the side airbag harness disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE SIDE AIRBAG SENSOR LH INFLATOR SIDE LH le S F3 5 Es ES ELE B5M1106 AB 64 DIAGNOSTIC C
159. crossbar 3 Rear crossbar OP 2 GENERAL DESCRIPTION OPTION PARTS 3 TRAILER HITCH 1 Receiver hitch 4 Ball mount clip Tightening torque N m kgf m ft Ib 2 Ball mount b Receiver cover T 95 9 7 70 3 Ball mount pin OP 3 GENERAL DESCRIPTION OPTION PARTS 4 REAR DIFFERENTIAL PROTECTOR DRO0021 1 Differential front member 4 Spacer Long Tightening torque N m kgf m ft lb 2 Differential rear member 5 Rear differential protector T 70 7 1 51 6 3 Spacer Short 69 Washer OP 4 REAR SPOILER OPTION PARTS 2 Rear Spoiler B INSTALLATION A REMOVAL Install in the reverse order of removal 1 Disconnect the ground terminal from battery 2 Open the trunk lid 7 5 N m 0 76 kgf m 5 5 ft Ib t th f high top 2 esconneeHinereonnecton anna od eg Retention cable to trunk hinge light 13 7 N m 1 4 kgf m 10 1 ft Ib Tightening torque Rear spoiler to trunk lid 1 Connector 2 Trunk hinge 4 Remove the retention cable with the trunk hinge lower side bolt 5 Remove the mounting nuts of rear spoiler 1 Retention cable 2 Mounting nut 6 Remove the rear spoiler with retention cable CAUTION Pay attention to avoid damage during removal or installation OP 5 CROSSBAR OPTION PARTS 3 Crossbar A REMOVAL 1 Remove the TORX bolt T30 from each end sup port 2 Rotate the lower clamp of each end support about 90 degress downward
160. crow foot wrenches will be needed Open end or flare nut wrenches will be needed for back up on the tube and hose fittings Applicator bottle Torque wrench G4M0571 A small APPLICATOR BOTTLE is recommended to apply refrigerant oil to the various parts They can be obtained at a hardware or drug store Manifold gauge set A MANIFOLD GAUGE SET with hoses can be obtained from either a commercial refrigeration supply house or from an auto shop equipment supplier G4M0572 G4M0573 AC 12 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C Description Refrigerant recovery system A REFRIGERANT RECOVERY SYSTEM is used for the recovery and reuse of A C system refrigerant after contaminants and moisture have been removed from the refrigerant G4M0574 Syringe A graduated plastic SYRINGE will be needed to add oil back into the system The syringe can be found at a pharmacy or drug store G4M0575 Vacuum pump A VACUUM PUMP in good working condition is necessary and may be obtained from either a commercial refrigeration supply house or an E automotive equipment supplier E G4M0576 Can tap A CAN TAP for the 397 g 14 oz can is available from an auto supply store G4M0577 AC 13 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C Tools and Equipment Thermometer G4M0578 Pocket THERMOMETERS are available from either industrial hard ware store or commercial refrige
161. ct the connector 1F in the test har ness F to connector AB7 4 Connect the airbag resistor to connector 3F in the test harness F 5 Connect the battery ground terminal and turn the ignition switch ON CHECK ROLL CONNECTOR 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the test harness F from the con nector AB7 3 Remove the lower cover panel disconnect aus the connector AB3 from AB8 and connect the connector 1F in the test harness F to con nector AB8 4 Connect the airbag resistor to connector SF in the test harness F 5 Connect the battery ground terminal and turn the ignition switch ON CHECK AIRBAG MAIN HARNESS 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the airbag resistor from the con nector in the test harness F 3 Remove the glove box Ref to AB 13 Pas senger s Airbag Module and disconnect the connectors AB10 and AB9 4 Disconnect the connector AB6 from the air bag control module and connect the connector 11 in the test harness or l2 Ref to AB 15 Airbag Control Module 5 Measure the resistance between connector 21 in the test harness or 12 and the connec tor SF in the test harness F Connector amp terminal 21 No 1 3F No 4 21 No 4 3F No 3 CHECK AIRBAG MAIN HARNESS Is the resistance more t
162. ct the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE SIDE AIRBAG SENSOR RH INFLATOR SIDE RH 9 gt D nN o gt Ed ys B5M1105 AB 62 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS check Ye CHECK SIDE AIRBAG MODULE Does the airbag warning light Replace the front Go to step 2 1 Turn the ignition switch OFF disconnect the operate properly seat with side air battery ground terminal and wait more than 20 bag module RH seconds Ref to SE 6 2 Disconnect the connector AB26 from the Front Seat seat belt pretensioner RH Hef to SB 8 Front Seat Belt 3 Disconnect the connector AB25 from AB24 and connect the connector 1F in the test harness F to AB24 4 Connect the airbag resistor to the connector 3F in the test harness F 5 Connect the battery ground terminal and turn the ignition switch ON CHECK SIDE AIRBAG HARNESS RH Is the voltage less than 1 V Replace the airbag Replace the body 1 Turn the ignition switch OFF disconnect the control module harness with side battery ground terminal and wait more than 20 Ref to AB 15 airbag harness seconds Airbag Control 2 Disconnect the airbag resistor from the test Module harness F 3 Disconnect the connector AB18 from the da airbag
163. ctor amp terminal Front and rear door B93 No 5 chassis ground Rear gate or trunk lid B93 No 4 chassis ground and ground circuit are OK Is the voltage O V when each Go to step 2 door rear gate or trunk lid is opened Is the voltage approx 10 V when each door rear gate or trunk lid is closed SL 24 Check the power supply and ground circuit Ref to INSPECTION Security System Check the harness for open circuits and shorts between the secu rity control module and fuse Check the harness for open circuits and shorts between the secu rity control module and fuse Repair the har ness Go to step 3 The door switch is Go to step 3 SECURITY SYSTEM SECURITY AND LOCKS Yes CHECK DOOR SWITCH Go to step 4 1 Disconnect the door switch harness connec tor 2 Measure the resistance between the door switch terminals Terminal Front LH No 1 No 3 Front RH No 1 No 3 Rear LH No 1 No 3 Rear RH No 1 No 3 Hear gate No 1 No 2 Trunk lid No 1 No 2 CHECK DOOR SWITCH Measure the resistance between the door switch terminals Terminal Front LH No 1 No 3 Is the resistance more than 1 MQ when the door switch is pushed Replace the door switch Is the resistance less than 10 when the door switch is released Check the harness Replace the door for open circuits and shorts between
164. ctors for safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE FRONT SUB SENSOR RH L 7273 gt lt 4 s16 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 26 27 28 50 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS 31 No 2 Chassis ground 31 No 4 Chassis ground CHECK AIRBAG MAIN HARNESS AND FRONT SUB SENSOR HARNESS RH 1 Disconnect the connector AB16 from the front sub sensor lt Ref to AB 18 Front Sub Sensor gt 2 Connect the connector IH in test harness H to the connector AB16 3 Measure the resistance between connector 31 in test harness or 12 and connector in the test harness H Connector amp terminal CHECK FRONT SUB SENSOR RH AND Is the resistance between Go to step 2 Go to step 3 FRONT SUB SENSOR HARNESS RH 750Q and 1 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the connector AB6 from the air bag control module and connect the connec tor 11 in the test harness or I2 lt Ref to AB 15 Airbag Control Module 3 Measure the resistance of the connector 31 in the test harness or I2 Connector amp terminal 31 No 2 No 4 CHECK FRONT SUB SENSOR RH AND Is the resistance more than 1 Replace the airbag Go to step 3 FRONT SUB SENSOR HARNESS RH MQ control module Measure the resistance betwee
165. d 3 Remove radio for repair AM and FM modes are weak or noisy ET 4 CIGARETTE LIGHTER SYSTEM ENTERTAINMENT 3 Cigarette Lighter System A SCHEMATIC 1 CIGARETTE LIGHTER lt Ref to WI 88 SCHEMATIC Front Accessory Power Supply System gt ET 5 RADIO BODY ENTERTAINMENT 4 Radio Body A REMOVAL 1 Disconnect the battery ground cable 2 Remove the center panel while disconnecting connector t F 1 3 Remove the fitting screws and slightly pull radio out from the center console 4 Disconnect the electric connectors and antenna feeder cord B INSTALLATION install in the reverse order of removal ET 6 FRONT SPEAKER ENTERTAINMENT 5 Front Speaker A REMOVAL 1 Disconnect the battery ground cable 2 Remove the front door trim lt Ref to El 37 RE MOVAL Front Door Trim gt 3 Remove the front speaker mounting screws 4 Disconnect the harness connector and remove the front speaker B INSTALLATION Install in the reverse order of removal f H i h L ECCVTUTRUEIVOTNHUTETNOUN HA TGA gn TS STUDIO EY Soe SO E aus t TURN ET 7 TWEETER ENTERTAINMENT 6 Tweeter A REMOVAL 1 Disconnect the battery ground cable 2 Remove the front door trim lt Ref to El 37 RE MOVAL Front Door Trim gt 3 Remove the tweeter Gon screws 4 Disconnect the har
166. d More than 1MQ RESUME M aW More than TMO ON Less than iQ Less than 19 ACCEL If NG replace the cruise control command switch CC 7 STOP AND BRAKE SWITCH CRUISE CONTROL SYSTEM 6 Stop and Brake Switch A REMOVAL 1 Disconnect the ground terminal from battery 2 Disconnect the connector from the switch and then remove the switch lt Ref to BR 55 REMOV AL Stop Light Switch gt B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the brake switch 1 and stop light switch 2 resistance B6M1564A Terminal No e Less than 10 More than TMO More than TMQ Stop light Less than 10 If NG replace the stop and brake switch CC 8 CLUTCH SWITCH 7 Clutch Switch A REMOVAL 1 Disconnect the ground terminal from battery 2 Disconnect the connector from the clutch switch and then remove the switch lt Ref to CL 26 DIS ASSEMBLY Clutch Pedal gt INSTALLATION Install in the reverse order of removal C INSPECTION Measure the clutch switch resistance Standard Less than 10 Clutch More than If NG replace the clutch switch CC 9 CRUISE CONTROL SYSTEM INHIBITOR SWITCH CRUISE CONTROL SYSTEM 8 Inhibitor Switch A REMOVAL 1 Disconnect the ground terminal from the battery 2 Disconnect the connector from the switch and then remove the switch lt Ref to AT 29 REMOV AL Inhibitor Swi
167. d terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the side airbag harness disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM PRETENSIONER LH 30 le JE 3t i ji B5M1108 AB 74 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Step Check Yes CHECK SEAT BELT PRETENSIONER Joes the airbag warning light 3eplace the seat 1 Turn the ignition switch OFF disconnect the perate properly elt pretensioner battery ground terminal and wait more than 20 LH Ref to SB seconds Front Seat 2 Disconnect the connector AB21 from the Jelt seat belt pretensioner LH Ref to SB 8 Front Seat Belt 3 Connect the connector 1L in the test har ness L to AB21 4 Connect the airbag resistor to the connector 3L in the test harness L 5 Connect the battery ground terminal and turn the ignition switch ON CHECK SIDE AIRBAG HARNESS LH 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the airbag resistor from the test harness L 3 Disconnect the connector AB20 from AB19 4 Disconnect the connectors AB17 and A
168. drill 4 Remove the ignition key lock 5 Use a new torn bolt Tighten the torn bolt to the end of the thread S6M0162A B INSPECTION 1 Remove the instrument panel lower cover 2 Remove the lower column cover 3 Unfasten the holddown clip which secures the harness and disconnect the connector of the igni tion switch from the body harness 4 Turn the ignition key plate to each position and measure the ignition switch resistance No 1 and No 2 less than 1 Q No 1 and No 2 less than 1 Q No 1 and No 4 No 2 and No 4 No 1 and No 3 less than 1 Q No 1 and No 4 No 3 and No 4 If NG replace the ignition switch SL 43 KEY LOCK CYLINDERS SECURITY AND LOCKS 21 Key Lock Cylinders 3 REAR GATE 1 Remove the rear gate trim Ref to El 52 RE A REPLACEMENT MOVAL Rear Gate Trim 1 FRONT DOOR 2 Remove the rod clamp Remove the lock plate Replace the k linder 1 Remove the door trim Ref to El 37 REMOV IURE ey Cynder AL Front Door Trim gt 2 Pull back the sealing cover 3 Move the front door glass downward 4 Remove the rod clamp Remove the bolt Re place the key cylinder Oy C er S 2 TRUNK LID 1 Remove the trunk lid release handle Ref to SL 40 Trunk Lid Release Handle 2 Remove the rod clamp Remove the lock plate Replace the key cylinder SL 44 SECURITY CONTROL MODULE SECURITY AND LOCKS
169. each part and confirm that the warning light operates properly e When inspecting the side airbag harness disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM AB18 AIRBAG CONTROL MODULE PRETENSIONER RH B5M1109 AB 72 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Gk w Ne _ CHECK SEAT BELT PRETENSIONER Does the airbag warning light Replace the seat Go to step 2 1 Turn the ignition switch OFF disconnect the operate properly belt pretensioner battery ground terminal and wait more than 20 RH Ref to SB seconds 8 Front Seat 2 Disconnect the connector AB26 from the Belt seat belt pretensioner RH Ref to SB 8 Front Seat Belt 3 Connect the connector 1L in the test har ness L to AB26 4 Connect the airbag resistor to the connector 8L in the test harness L 5 Connect the battery ground terminal and turn the ignition switch ON CHECK SIDE AIRBAG HARNESS RH Is the resistance less than 10 1 Turn the ignition switch OFF disconnect the Q battery ground terminal and wait more than 20 seconds 2 Disconnect the airbag resistor from the test harness L 3 Disconnect the connector AB25 from AB24 4 Disconnect the connectors AB17 and AB18 from the airbag control module Ref to AB 15 Airbag Control Module 5 Connect the connector 11 in the test har ness or I2 to the con
170. ear gloves and goggles Wash your hands afterwards Do not re use a seat belt with a deployed preten sioner again e f the material gets in your eyes or on your skin during deployment wash it away with clean water and then consult a doctor SB 5 PRETENSIONER CONNECTOR SEAT BELT SYSTEM 2 Pretensioner Connector A OPERATION 1 How to disconnect 1 Move the slide lock A in the direction of the arrow 2 Pull the connector B in the direction of the arrow with slide lock A moved CAUTION When pulling be sure to hold onto the connec tor and not the wire 2 How to connect Holding connector A and push it in carefully until a connecting sound is heard CAUTION e Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked SB 6 INSPECTION LOCATIONS AFTER A COLLISION SEAT BELT SYSTEM 3 Inspection Locations After a Collision A INSPECTION Check for the following and then replace with new parts if necessary Center pillar lower garnish is discolored or cracked e Wire harness and or connector is damaged SB 7 FRONT SEAT BELT SEAT BELT SYSTEM 4 Front Seat Belt 2 INNER BELT FRONT 1 Disconnect the connector A REMOVAL 2 Remove the anchor bolt and then detach the in 1 OUTER BELT FRONT ner belt 1 Fold backrest all the way forward and then move the front seat all the way forward 2 Tu
171. ect the connector 1F in the test har ness F to the connector AB8 5 Connect the airbag resistor to connector in the test harness F 6 Connect the battery ground terminal and turn the ignition switch ON CHECK AIRBAG MAIN HARNESS 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the airbag resistor from the con nector 3F in test harness F 3 Remove the glove box and disconnect the connectors AB10 and AB9 4 Disconnect the connector AB6 from the air bag control module and connect the connector 11 in the test harness or 12 Ref to AB 15 Airbag Control Module 5 Connect the battery ground terminal and turn the ignition switch ON Engine OFF 6 Measure the voltage between connector 21 in the test harness or I2 and the chassis ground Connector amp terminal 21 No 4 Chassis ground 21 No 1 Chassis ground operate properly Is the voltage less than 1 V Replacethe airbag Replace the body control module harness with air Ref to AB 15 bag main harness Airbag Control Module AB 41 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS D TROUBLE CODE 16 DIAGNOSIS Airbag main harness circuit Passenger is shorted to the power supply e Airbag module harness Passenger is shorted to the power supply e Passenger s airbag module
172. ed AIRBAG SYSTEM DIAGNOSTICS 2 DRIVER S AIRBAG PASSENGER S AIR BAG AND SIDE AIRBAG 1 How to disconnect 1 Push the lock arm A 2 With lock arm A pushed in move the slide lock B in the direction of the arrow B5M1153A 3 With slide lock B pulled remove the lock arm A to its original position and then pull in the direction of the arrow and separate the con nector CAUTION When pulling be sure to hold onto the connec tor and not the wire 2 How to connect Holding the connector and push it in carefully until a connecting sound is heard CAUTION Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked AB 21 AIRBAG CONNECTOR AIRBAG SYSTEM DIAGNOSTICS 3 FRONT SUB SENSOR SIDE AIRBAG SENSOR 1 How to disconnect 1 Holding the outer part A pull it in the direc tion of the arrow CAUTION When pulling be sure to hold onto the connec tor and not the wire 2 How to connect Holding the connector and push it in carefully until a connecting sound is heard CAUTION e Outer A moves back and so do not put your hand on the outer part e Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked 4 PRETENSIONER 1 How to disconnect 1 Move the slide lock A in the direction of the arrow 2 Pull the connector B in the direction of the
173. ed Connector amp terminal 5M No 2 Chassis ground 21 No 6 Chassis ground CHECK FUSE NO 6 IN JOINT BOX 1 Confirm that the ignition switch is turned OFF 2 Remove the fuse No 6 in joint box and per form visual inspection Go to step 3 Replace the body harness with air bag main harness Is the resistance more than 1 9 Go to step 4 Replace the body harness with air bag main harness Is the fuse No 6 blown Replace the fuse No 6 If the fuse No 6 is blown again repair the body harness Repair the body harness AB 49 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS J TROUBLE CODE 31 DIAGNOSIS e Front sub sensor harness RH circuit is shorted Front sub sensor harness RH circuit is open Front sub sensor RH is faulty e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module conne
174. edee siise T o m 2 Refrigerant Pressure with Manifold Gauge 15 Refrigerant Recovery PrTOCOQOULF6 root pero Verb apr oa EE EVI I HER ca VR 16 Refrigerant Charging Procedure 17 Belngerant Leak OHeek ss voi tq mI ru iB ga Nt 20 Compressor IM et 21 Blower Motor Unit Assembly ken Dee e 22 BIGWEF 23 PIS ALET 24 CONTO 25 COITIDIeSSO uisi statali O NDA 26 Condense D UBL Mont 27 Heater and Cooling Unit orienta a br debes 28 Evapora PCR MA 29 Hose and dfi esas aso A e cde 30 Relay and Bil cR 31 Pressure Switch Dual SWIC 5 Mae Vua 32 Air Ventanllgu ser eret Ep EEE 33 Heater PI Te RN E 34 Heater Vent DUCE RUE Dare Sr ERE ON eee 35 General DIBgriosll6S aei to eO cte o un DU eir docu eed tt 36 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 1 General Description A SPECIFICATIONS 1 HEATER SYSTEM e Mode selector switch HEAT e Temperature control switch FULL HOT 5 0 kW 4 300 kcal h 17 062 BTU Temperature difference between hot water h or more and i
175. een the transmis sion control module connector B56 turbo model or B55 non turbo model and chassis ground Connector amp terminal Turbo model B56 No 17 Chassis ground Non turbo model B55 13 Chassis ground CHECK HARNESS BETWEEN TRANSMIS SION CONTROL MODULE AND COMBINA TION METER 1 Turn the ignition switch to OFF 2 Disconnect the connector from the transmis sion control module and combination meter 3 Measure the resistance between the trans mission control module harness connector B56 turbo model or B55 non turbo model and combination meter harness connector 110 Connector amp terminal Turbo model B56 No 17 i10 No 2 Non turbo model B55 No 13 110 No 2 Check the trans mission control module lt Ref to AT 2 Basic Diag nostic Procedure Is the resistance less than 10 Q Check the speedo Repair the wiring meter lt Ref to IDI 13 REMOVAL Speedometer gt 5 CHECK ENGINE CONTROL MODULE Yes CHECK ENGINE CONTROL MODULE SIG 15 the voltage 0 lt 13Vor Go to step 2 Check the engine NAL more control module 1 Start the engine Ref to 2 Measure the voltage between the engine EN SOHC 2 control module connector B136 turbo model Basic Diagnostic or B134 non turbo model and engine Procedure or ground Ref to EN DOHC Connector amp terminal TURBO 2 Bas
176. els positioned straight ahead make sure that the vehicle moves straight ahead 2 Turn the ignition switch OFF 3 Disconnect the ground terminal from battery and wait for at least 20 seconds before starting work 4 Using TORX BIT T30 remove the two TORX bolts on the side of steering wheel TORX BIT T30 H5M0662A 5 Disconnect the airbag connector on the back of airbag module and then remove the airbag mod 6 Refer to the CAUTION for handling of a re moved airbag module lt Ref to AB 3 CAUTION General Description gt C INSTALLATION 1 Install in the reverse order of removal CAUTION Do not allow harness and connectors to inter fere or get tangled up with other parts D INSPECTION Check for the following and replace the damaged parts with new parts e Airbag module harness connector and mount ing bracket are damaged AB 12 PASSENGER S AIRBAG MODULE AIRBAG SYSTEM 5 Passenger s Airbag Module A CAUTION Refer to the CAUTION of General Description be fore handling the airbag module Ref to AB 3 CAUTION General Description B REMOVAL 1 Turn the ignition switch OFF 2 Disconnect the ground terminal from battery and wait for at least 20 seconds before starting work 3 Remove the glove box lt Ref to El 39 REMOV AL Glove Box gt 4 Detach the airbag connector from the support beam bracket and then disconnect the airbag con nector 5
177. emove the rear gate latch assembly B INSTALLATION Install in the reverse order of removal CAUTION Make sure the lock works properly after instal lation C INSPECTION 1 Make sure the rod is not deformed 2 Make sure the lever and rod work smoothly SL 37 SECURITY AND LOCKS REAR GATE LATCH LOCK ACTUATOR SECURITY AND LOCKS 15 Rear Gate Latch Lock Actua tor A REMOVAL 1 Remove the rear gate latch assembly lt Ref to SL 37 REMOVAL Rear Gate Latch Assembly gt 2 Loosen two screws to remove the rear gate lock actuator B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Disconnect the door lock actuator harness con nector 2 Connect the battery to the door lock actuator ter minals Actuator operation No 1 and No 2 Unlocked Locked No 2 and No 1 Locked Unlocked If NG replace the rear gate latch lock actuator SL 38 TRUNK LID LOCK ASSEMBLY SECURITY AND LOCKS 16 Trunk Lid Lock Assembly A REMOVAL 1 Remove the trunk lid key cylinder rod clamp 2 Loosen two bolts to remove the trunk lid lock as sembly B INSTALLATION Install in the reverse order of removal CAUTION Apply grease to the parts that rub e Make sure the lock works properly after in stallation C INSPECTION 1 Check the striker for bending or abnormal wear 2 Check the safety lever for improper movement 3 Check other levers a
178. en the screws to remove the side air vent grille B INSTALLATION Install in the reverse order of removal C INSPECTION The direction and amount of air should be adjusted smoothly The adjustment should be kept in each position AC 33 HEATER DUCT HVAC SYSTEM HEATER VENTILATOR AND A C 19 Heater Duct A REMOVAL 1 Remove the heater unit lt Ref to AC 28 Remov al gt 2 Remove the front seat lt Ref to SE 6 REMOV AL Front Seat gt 3 Remove the front side sill cover 4 Pull off the floor mat to remove the heater duct B INSTALLATION install in the reverse order of removal AC 34 HEATER VENT DUCT HVAC SYSTEM HEATER VENTILATOR AND A C 20 Heater Vent Duct A REMOVAL 1 Remove the instrument panel lt Ref to El 42 REMOVAL Instrument Panel Assembly gt 2 Remove the screws 3 Remove the heater vent duct B INSTALLATION Install in the reverse order of removal AC 35 GENERAL DIAGNOSTICS HVAC SYSTEM HEATER VENTILATOR AND A C 21 General Diagnostics A INSPECTION Doesn t move Blower motor Strange noise Doesn t move Compressor Cold air not emitted Warm air not emitted Temperature of air from vents does not change Unable to switch blow vents Unable to switch suction vents Repair order Fuse Blower motor relay Blower motor Blower motor resistor Blower switch Wire harness Blower motor Refrigerant Fuse
179. er Trim 7 Remove the quarter upper trim Ref to El 47 SEDAN REMOVAL Rear Quarter Trim 8 Remove the clips and then remove the roof trim 2 WAGON 1 Disconnect the ground terminal from battery 2 Remove the room light Ref to LI 26 REMOV AL Room Light 3 Remove the sun visor and hook on both sides Ref to El 49 REMOVAL Sun Visor 4 Remove the assist grips A B5M1025A 5 Remove the upper inner trim Ref to El 45 RE MOVAL Upper Inner Trim 6 Remove the rear quarter upper trim shown in the figure 7 Remove the rear rail trim A 8 Remove the rear quarter upper trim B of both sides El 50 ROOF TRIM EXTERIOR INTERIOR TRIM 9 Remove the clips and then remove the roof trim B INSTALLATION Install in the reverse order of removal E 51 REAR GATE TRIM EXTERIOR INTERIOR TRIM 23 Rear Gate Trim A REMOVAL CAUTION Be careful not to damage the clips or their holes 1 Remove the clips and detach the rear gate trim B INSTALLATION Install in the reverse order of removal El 52 REAR SHELF TRIM 24 Rear Shelf Trim A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the high mounted stop light 3 Remove the rear quarter upper trim Ref to El 47 REMOVAL Rear Quarter Trim 4 Remove the seat belt center lower anchor bolt 5 Remove the rear shelf trim m B INSTALLATION install in t
180. ero point this is a sign of leakage Check pipe connector points repair them make sure there is no leakage by air bleeding 9 Following the can tap operation manual instruc tions install it to the refrigerant can Tap valve Center manifold 4 iii hose 10 Disconnect the center manifold hose from the _vacuum pump and connect the hose to the tap valve 11 When a 13 6 kg 30 Ib refrigerant container is used measure the refrigerant amount in use using a weight scale Refrigerant container HFC 134a 12 Confirm that all the 3 hoses are tightly connect ed to the manifold gauge set Low pressure gauge Compound pressure gauge High pressure gauge 13 Open the valve on the HFC 134a source 14 Loosen the center hose connection on the manifold gauge set if applicable press a purge valve on the manifold gauge set only for a couple of seconds to allow the air in the center hose to es cape by the refrigerant 15 Carefully open the high pressure valve with the engine stopping CAUTION Do not open the low pressure valve Low pressure gauge Compound pressure High pressure CAUTION Never run the engine during charging from the high pressure side 16 Close the high pressure valve when the low pressure gauge reaches 98 kPa 1 kg cm 14 psi Using a leak tester check the system for leaks If any leakage is found after the refrigerant recov ery is completed repair the appl
181. everse order of removal CAUTION e During installation make sure that the seat belts are not twisted e After installation make sure that the seat belts can be smoothly extended and wound 5 OUTER BELT CENTER WAGON Install in the reverse order of removal CAUTION During installation make sure that the seat belts are not twisted e After installation make sure that the seat belts are smoothly extended and wound 6 INNER BELT WAGON Install in the reverse order of removal CAUTION During installation make sure that the seat belts are not twisted C INSPECTION 1 OUTER BELT SIDE SEDAN Check for the following and replace with new parts if necessary Seat belt is slackened bent or frayed Seat belt is abnormally wound or extended 2 OUTER BELT CENTER SEDAN Check for the following and replace with new parts if necessary e Seat belt is slackened bent or frayed Seat belt is abnormally wound or extended 3 INNER BELT SEDAN Check for the following and replace with new parts if necessary e Inner belt is deformed or damaged e Seat belt buckle is engaged improperly 4 OUTER BELT SIDE WAGON Check for the following and replace with new parts if necessary e Seat belt is slackened bent or frayed Seat belt is abnormally wound or extended 5 OUTER BELT CENTER WAGON Check for the following and replace with new parts if necessary e Seat belt is slackened bent
182. ew parts e Side airbag sensor is cracked or deformed e Mounting bracket is cracked or deformed e Connector is scratched or cracked e Side airbag is deployed operating side 11 STEERING SHAFT 8 SIDE AIRBAG SENSOR HARNESS Check for the following and replace the damaged parts with new parts Harness is open lead wire is exposed and cor rugated tube is noticeably cracked Connector is scratched or cracked 9 MAIN HARNESS Check for the following and replace the damaged parts with new parts Harness is open lead wire is exposed and cor rugated tube is noticeably cracked Connector is scratched or cracked 10 ROLL CONNECTOR Check for the following and replace the damaged parts with new parts Combination switch or steering roll connector is cracked or deformed Check for the following and replace the damaged parts with new parts Overall length of steering column should be within specifications Specifications Overall length L 825 7 1 5 mm 32 5 0 06 Soe 1 E If necessary replace it with new part l aS CI D E AB 11 DRIVER S AIRBAG MODULE AIRBAG SYSTEM 4 Driver s Airbag Module A CAUTION Refer to the CAUTION of General Description be fore handling the airbag module lt Ref to AB 3 CAUTION General Description gt B REMOVAL 1 Position the front wheels straight ahead After moving a vehicle more than 5 m 16 ft with front whe
183. g light 1 Turn the ignition switch OFF disconnect the turned off battery ground terminal and wait more than 20 seconds 2 Connect the connector AB1 to B31 3 Disconnect the connectors AB3 and 8 4 Remove the glove box and disconnect the connectors AB10 and AB9 5 Disconnect the connector AB6 from the air bag control module and connect the connector 11 in the test harness or 12 Ref AB 15 Airbag Control Module 6 Connect the battery ground terminal and turn the ignition switch ON 7 Connect the connectors 41 and 51 in the test harness or 12 NOTE After problem has been eliminated disconnect connectors 41 and 51 CHECK GROUNDING CIRCUIT Is the resistance less than 10 1 Turn the ignition switch OFF disconnect the 02 battery ground terminal and wait more than 20 seconds 2 Disconnect the connector AB6 from the air bag control module 3 Connect the connector 11 in the test har ness or 12 to body harness connector AB6 4 Measure the resistance between connector 2l in the test harness or I2 and the chassis ground Connector amp terminal 21 No 9 Chassis ground 21 No 10 Chassis ground Replace the body harness with air bag main harness Replace the airbag Repair body control module grounding circuit Ref to AB 15 Airbag Control Module AB 29 AIRBAG WARNING LIGHT FAILURE AIRBAG SYSTEM DIAGNOSTICS B
184. ght amount of leakage about 28 g 1 0 oz per year This is not a problem 9 Starting from the connection between the low pressure tube and evaporator check the system for leakage along the high pressure side through the compressor The following items must be checked thoroughly e Connection between the tube and tube fitting Connection between 2 parts e Connection between the tube and nut 10 Visually check the rubber area of the flexible hose for cracks Check the entire length of the flexible hose espe cially the connection with the metal hose end CAUTION Carefully check the external surface of hoses and tubes at approx 25 mm 0 98 in per sec ond Flexible hose 11 Disconnect the drain hose from the evaporator case and check the hose end for at least 10 sec onds After the test is finished reconnect the drain hose 12 Turn the ignition key to ON position and run the blower at high speed for 1 minute Stop the blower to check the ventilation grille on the instrument pan el While moving the tester closer to the grille run the blower for 1 or 2 seconds then stop it Check the grille at that point for at least 10 seconds 13 Check the valve in the service port 14 Visually check the rubber seal in the service port cap AC 20 COMPRESSOR OIL 6 Compressor Oil A OPERATION NOTE Before making repairs conduct the oil return oper ation to return the compressor oil in circulati
185. ground Connector amp terminal B176 No 16 chassis ground CHECK KEY WARNING SWITCH Is the resistance less than 1 1 Disconnect the key warning switch harness Q connector 2 Insert the key into the ignition switch LOCK position 3 Measure the resistance between the key warning switch terminals Terminal No 1 No 2 CHECK KEY WARNING SWITCH 1 Remove the key from the ignition switch 2 Measure the resistance between the key warning switch terminals Terminal No 1 No 2 Is the fuse blown 15A Go to step 2 Is the voltage more than 10 V Go to step 3 Go to step 4 Is the voltage 0 V The key warning switch is OK Go to step 4 Go to step 5 Replace the key warning switch Check the following e Harness for open circuits and shorts between the key warning switch and fuse e Harness for open circuits and shorts between the keyless entry contro module and key warning switch Is the resistance more than 1 MQ Replace the key warning switch 9 CHECK HORN OPERATION Yes CHECK HORN OPERATION Does the horn sound Go to step 2 Check the horn cir Make sure the horn sounds when the horn cuit switch is pushed CHECK HORN OPERATION Does the horn sound Replace the key Checkthe harness 1 Disconnect the keyless entry contro module less entry control for open circu
186. han 1 Measure the resistance of the connector 21 in MQ the test harness or 12 Connector amp terminal 2l No 1 No 4 21 No 4 Chassis ground 21 No 1 Chassis ground Replace the driver s airbag module Ref to AB 12 Driver s Airbag Module Go to step 2 Does the airbag warning light Go to step 3 operate properly Replace the roll connector lt Ref to AB 17 Roll Connector Is the resistance less than 10 Q Go to step 4 Replace the body harness with air bag main harness Replace the airbag Replace the body control module harness with air lt Ref to AB 15 bag main harness Airbag Control Module gt AB 37 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS B TROUBLE CODE 12 DIAGNOSIS e Airbag main harness circuit is open shorted or shorted to ground e Airbag module harness Passenger circuit is open shorted or shorted to ground e Passenger s airbag module is faulty e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the
187. hart with Diagnostic Trouble Code Ref to CC 34 DTC 35 AND 36 ACTUATOR MOTOR Diagnostics Chart with Diagnostic Trouble Code Ref to CC 34 DTC 35 AND 36 ACTUATOR MOTOR Diagnostics Chart with Diagnostic Trouble Code gt lt Ref to CC 36 DTC 37 ACTUATOR MOTOR CLUTCH Diagnostics Chart with Diagnostic Trouble Code gt lt Ref to CC 38 DTC 38 MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY Diagnostics Chart with Diagnostic Trouble Code gt LIST OF DIAGNOSTIC TROUBLE CODE DTC CRUISE CONTROL SYSTEM DIAGNOSTICS Contents of diagnosis Motor is overloaded Current flows through motor more frequently than under Ref to CC 39 DTC 39 normal conditions MOTOR IS OVER LOADED Diagnostics Chart with Diagnostic Trouble Code gt lt Ref to CC 28 DTC 21 24 25 AND 2A CRUISE CONTROL MODULE BUILT IN RELAY CPU RAM Diagnostics Chart with Diagnostic Trouble Code gt Cruise control module self diagnosis function senses abnormality Cruise control module is abnormal CC 27 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS 8 Diagnostics Chart with Diagnostic Trouble Code A DTC 21 24 25 AND 2A CRUISE CONTROL MODULE BUILT IN RELAY CPU RAM DIAGNOSIS e Poor welding of built in relay of cruise control module e Failure of built in CPU RAM of cruise control module TROUBLE SYMPTOM e Cruise cont
188. he driver passenger replace them with new parts side airbag modules and pretensioner Never re use a deployed airbag and pretension er e When checking the system be sure to use a dig ital circuit tester Use of an analog circuit tester may cause the air bag to activate erroneously NO GOOD G5M0302 AB 4 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS Do not allow water or oil to come in contact with e Install the wire harness securely with the speci the connector terminals Do not touch the connec fied clips to avoid interference or tangled up with tor terminals other parts NO GOOD e The airbag module driver passenger side and e When painting or performing sheet metal work pretensioner must not be disassembled on the front part of the vehicle including the front wheel apron front fender and front side frame re move the front sub sensors and wire harness of the airbag system e When painting or performing sheet metal work on the side of the vehicle including the side sill center pillar and front and rear doors remove the side airbag sensors and wire harness of the airbag system f any damage opening or rust is found on the airbag system wire harness do not attempt to re pair using soldering equipment Be sure to replace the faulty harness with a new genuine part NO GOOD NO GOOD AB 5 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS
189. he ground termina from battery 2 Loosen the screws and clips to remove the lower cover 3 Remove the glove box Ref to El 39 REMOV AL Glove Box 4 Remove the center console panel lt Ref to AC 25 REMOVAL Control Unit 5 Remove the passenger airbag module Ref to AB 13 Passenger s Airbag Module 6 Loosen the four screws and two nuts to remove the lower console panel 8 Remove the two nuts and disconnect the two connectors El 42 INSTRUMENT PANEL ASSEMBLY EXTERIOR INTERIOR TRIM 9 Remove the instrument panel mounting bolts BOO121 10 Remove the instrument panel CAUTION CAUTION e Take care not to scratch the instrument panel Do not pull the harness when disconnecting the and related parts connector NOTE If necessary make matching marks for easy reas sembly El 43 INSTRUMENT PANEL ASSEMBLY EXTERIOR INTERIOR TRIM e When storing the removed instrument panel B INSTALLATION place it standing up on the floor Install in the reverse order of removal CAUTION Be careful not to snag the harness e Make sure to connect the harness connector e Take care not to scratch the instrument panel and related parts NOTE When setting the instrument panel into position push the hook into grommet A on the body panel El 44 UPPER INNER TRIM 18 Upper Inner Trim A REMOVAL 1 Remove the lower inner trim Ref to El 46 RE MOVAL Lower Inner
190. he lever and rod work smoothly SL 30 FRONT DOOR LOCK ACTUATOR SECURITY AND LOCKS 8 Front Door Lock Actuator A REMOVAL 1 Remove the front door latch assembly lt Ref to SL 28 REMOVAL Front Inner Remote gt 2 Loosen two screws to remove the front door lock acutuator B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Disconnect the door lock actuator harness con nector 2 Connect the battery to the door lock actuator ter minals No and No 1 Unlocked Locked No 1 and No 3 Locked Unlocked If NG replace the door lock actuator SL 31 REAR INNER REMOTE SECURITY AND LOCKS 9 Rear Inner Remote A REMOVAL 1 Remove the rear door trim Ref to El 38 RE MOVAL Rear Door Trim 2 Remove the sealing cover Ref to EB 17 RE MOVAL Rear Sealing Cover 3 Remove the screw and the two rod joints 4 Remove the inner remote B INSTALLATION Install in the reverse order of removal CAUTION Make sure the lock works properly after instal lation C INSPECTION 1 Make sure the rod is not deformed 2 Make sure the lever and rod work smoothly 3 Make sure the child safety lock on rear doors work properly when applicable SL 32 REAR OUTER HANDLE SECURITY AND LOCKS 10 Rear Outer Handle A REMOVAL 1 Remove the rear door trim lt Ref to El 38 RE MOVAL Rear Door Trim gt 2 Remove the
191. he reverse order of removal El 53 EXTERIOR INTERIOR TRIM TRUNK TRIM EXTERIOR INTERIOR TRIM M 25 Trunk Trim A REMOVAL 1 Remove the rear seat backrest Ref to SE 11 SEDAN REMOVAL Rear Seat 2 Remove the clip A 3 Loosen the clips and then detach the trunk rear trim B 4 Loosen the clips to remove the trunk side trim C INSTALLATION Install in the reverse order of removal El 54 FLOOR MAT EXTERIOR INTERIOR TRIM 26 Floor Mat A REMOVAL 1 Remove the front seats lt Ref to SE 6 REMOV AL Front Seat gt 2 Remove the rear seat cushion lt Ref to SE 11 REMOVAL Rear Seat gt 3 Remove the console box lt Ref to El 41 Con sole Box gt 4 Remove the side sill front cover side sill rear cover and center pillar lower trim lt Ref to El 46 REMOVAL Lower Inner Trim 5 Remove the clips from floor mat 6 Remove the mat hook 7 Remove the mat from toe board area 8 Remove the mat from rear heater duct 9 Roll the mat and then take it out of opened rear door B INSTALLATION Install in the reverse order of removal NOTE e Secure the mat firmly with hook and Velcro tape Insert the mat edge firmly into the groove of side sill cover EI 55 LUGGAGE FLOOR MAT EXTERIOR INTERIOR TRIM 27 Luggage Floor Mat A REMOVAL Remove the clips then detach the rear floor mats and boxes
192. i Connector amp terminal tion switch B59 No 1 chassis ground CHECK HARNESS BETWEEN INTERRUPT 15 the resistance less than 10 Replace the secu Check the harness RELAY AND SECURITY CONTROL MOD rity control mod for open circuits ULE ule and shorts Measure the resistance between the interrupt between the inter relay harness connector terminal and security rupt relay and control module harness connector terminal security control Connector amp terminal module B59 No 4 B93 No 15 11 CHECK IGNITION SWITCH CIRCUIT CHECK IGNITION SWITCH SIGNAL Is the voltage more than 10 V The ignition switch Checkthe harness 1 Disconnect the security control module har circuit is OK for open circuits ness connector and shorts 2 Turn the ignition switch ON between the secu 3 Measure the voltage between the harness rity control module connector terminal and chassis ground and ignition switch Connector amp terminal B93 No 2 chassis ground SL 27 FRONT INNER REMOTE SECURITY AND LOCKS 5 Front Inner Remote A REMOVAL 1 Remove the door trim lt Ref to El 37 REMOV AL Front Door Trim gt 2 Remove the sealing cover lt Ref to EB 14 RE MOVAL Front Sealing Cover gt 3 Remove the screw and the two rod joints 4 Remove the front inner remote B INSTALLATION Install in the reverse order of removal CAUTION Make sure the lock works properly after instal
193. ic Turbo model Diagnostic Proce B136 No 9 Engine ground dure Non turbo model B134 No 30 Engine ground IDI 7 COMBINATION METER SYSTEM INSTRUMENTATION DRIVER INFO CHECK HARNESS BETWEEN COMBINA 15 the resistance less than 10 Check the tachom Repair the wiring TION METER AND ENGINE CONTROL eter Ref to IDI harness 14 REMOVAL Tachometer gt CHECK FUEL LEVEL SENSOR Is the resistance 0 5to2 59 Go to step 2 Replace the fuel 1 Remove the fuel level sensor Ref to FULL and 50 to 52 Q level sensor FU SOHO 62 REMOVAL Fuel Level Sen EMPTY Sor or Ref to FU DOHC TURBO 62 REMOVAL Fuel Level Sensor 2 Measure the resistance between the fuel ievel sensor terminals when setting the float to FULL and EMPTY position Terminals No 2 No 3 CHECK FUEL SUB LEVEL SENSOR Is the resistance 0 5to2 5Q 30 to step 3 1 Remove the fuel sub level sensor Ref to FULL and 42 to 44 Q FU SOHC 63 REMOVAL Fuel Sub Level EMPTY Sensor gt or lt Ref to FU DOHC TURBO 63 REMOVAL Fuel Sub Level Sensor gt 2 Measure the resistance between the fuel sub level sensor terminals when setting the float to FULL and EMPTY position Terminals No 1 No 2 ao to step 5 Replace the fuel sub level sensor Is the resistance less than 10 2 CHECK HARNESS BETWEEN FUEL SUB LEVEL SENSOR AND COMBINATION
194. icable area 17 After confirming that there are no leaks with the leak test charge the required amount of refrigerant CAUTION Never run the engine during charging from the high pressure side 18 Close the high pressure valve when e the readings of low high pressure gauges be come almost equal after the charging speed is re duced e the HFC 134a source becomes empty or e the system is filled with the gas AC 18 REFRIGERANT CHARGING PROCEDURE 19 If the HFC 134a source is empty close the high pressure valve close the valve on the can tap and replace the HFC 134a source with a new one to restart the operation Low pressure gauge Compound pressure gauge High pressure gauge 20 Confirm that both the low high pressure valves can be closed Start the engine with the A C switch OFF 21 Quickly repeat ON OFF cycles a few times to prevent initial compressor damage 22 Set up the vehicle to the following status A C switch ON e Engine running at 1 500 rpm e Blower speed setting to HI e Temperature setting to MAX COOL e Air inlet setting to RECIRC e Windows open 23 While reading the low pressure gauge careful ly open the low pressure valve with the refrigerant source connected and the service hose purged CAUTION Never open the high pressure valve with the en gine is running 24 Adjust the refrigerant flow to maintain the pres sure on the low pressure side
195. icle Brought In Odometer Reading Date Problem Occurred Registration Year Weather Fine Cloudy Q Rainy Li Snowy Other C F Road Condition Level road C Uphill Downhill Rough road Others J Starting L1 Idling Vehicle Operation Driving Constant Speed Q Acceleration Q Deceleration Steering wheel turn Other Details of Problem Check Airbag Warning Light Ly Remains ON Remains OFF Check DTC LJ Normal Code Trouble Code Code AB 3 GENERAL DESCRIPTION AIRBAG SYSTEM DIAGNOSTICS 3 General Description e When checking use a test harness Do not di rectly apply the tester probe to any connector termi A CAUTION nal of the airbag e When servicing a vehicle be sure to turn the ig nition switch OFF disconnect the ground terminal from the battery and wait for more than 20 seconds before starting work The airbag system is fitted with a backup power source If the airbag system is serviced within 20 seconds after the ground terminal is disconnected it may inflate NO GOOD G5M0293 NO GOOD G5M0292 e f the sensors airbag module airbag contro module pretensioner and harness are deformed or damaged replace them with new genuine parts NO GOOD Test harness G5M0291 e Do not use the airbag system and pretensioners G5M0294 on other vehicles When replacing parts be sure to Do check continuity of t
196. in the test harness or I2 and the connec tor in the test harness F Connector amp terminal 21 No 2 No 3 2 No 5 No 4 CHECK AIRBAG MAIN HARNESS Measure the resistance of the connector 21 in the test harness or 12 Connector amp terminal 21 No 2 No 5 21 No 2 Chassis ground 21 No 5 Chassis ground Go to step 2 Go to step 3 Replace the body harness with air bag main harness Is the resistance more than 1 MQ Replace airbag control module lt Ref to AB 15 Airbag Control Module gt Replace the body harness with air bag main harness AB 39 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS C TROUBLE CODE 15 DIAGNOSIS e Airbag main harness circuit Driver is shorted to the power supply e Airbag module harness Driver is shorted to the power supply Roll connector is shorted to the power supply e Driver s airbag module is faulty e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operate
197. int Pomttopont H 10 to 24 935 36 81 Sedan 21 RH to 22 RH 985 38 78 1 122 44 17 Wagon 27 LH to 22 LH 12 RH to 12 LH 1 067 4201 9 RHigoRH t a OO BS 14 DATUM DIMENSIONS BODY STRUCTURE 3 WAGON SEDAN REAR STRUCTURE 2 ie x lt gt mE BOO0441 Unit mm in H 41 62 LH to 65 915 36 02 70 RH to 70 LH 1 060 41 73 62 RH to 73 R 762 30 00 70 RH to 73 RH 948 37 32 62 LH to 73 LH 762 30 00 70 LH to 73 LH 948 37 32 62 RH to 73 LH 1 561 61 46 70 RH to 73 LH 1 542 60 71 62 LH to 73 RH 1 561 61 46 70 LH to 73 RH 1 542 60 71 62 RH to 74 RH 592 23 31 Wagon 70 RH to 75 RH 1 443 56 81 62 LH to 74 LH 65 to 67 RH 70 LH to 91 RH 949 37 36 Sedan 65 to 91 RH 91 RH to 91 LH 1 205 47 44 65 to 91 LH 304189 S ep AM BS 15 DATUM DIMENSIONS BODY STRUCTURE 4 WAGON FRONT STRUCTURE Unit mm in Pemttopon 1 Dimension Pomttopont Dimension 1 538 60 55 83 LH to 65 65 to 77 LH 83 RH to 65 65 to 77 G3 RH to 72 LH 71 RH to 72 RH 33 LH to 72 RH 1 344 52 91 71 LH to 72 LH 1 223 48 15 BS 16 DATUM DIMENSIONS BODY STRUCTURE 5 WAGON REAR STRUCTURE Unit mm in RH LH
198. iring harness is routed near the electrical parts and switch Horn 5 Trunk room light switch Sedan 8 Passive arm connector rear gate latch switch Wagon 9 Security horn relay 6 Door switch Security indicator light in combi 7 Keyless entry control module 11 Horn relay in main fuse box 10 Interrupt relay e All airbag system wiring harness and connectors are colored yellow Do not use the electrical test equipment on these circuits Be careful not to damage the Airbag system wiring harness when servicing the ignition key cylinder SL 6 GENERAL DESCRIPTION SECURITY AND LOCKS C PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925580000 PULLER Used for removing trim clip c B5M1120 2 GENERAL TOOLS TOOL NAME REMARKS Used for measuring resistance and voltage Drill Used for replacing ignition key lock DOOR LOCK CONTROL SYSTEM SECURITY AND LOCKS 2 Door Lock Control System A SCHEMATIC 1 DOOR LOCK CONTROL lt Ref to WI 64 SCHEMATIC Door Lock System gt SL 8 DOOR LOCK CONTROL SYSTEM SECURITY AND LOCKS B INSPECTION 1 SYMPTOM CHART Sympiom The door lock control system does 1 Check the fuse lt Ref to SL 9 CHECK FUSE not operate INSPECTION Door Lock Control System gt 2 Check the power supply and ground circuit for Ref to SL 10 CHECK POWER the integrated module SUPPLY AND GROUND CIRCUIT INSPECTION Door Lo
199. is faulty e Airbag control module is faulty CAUTION Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly When inspecting the airbag main harness disconnect the airbag module connector of the driver and passenger seats for safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE INFLATOR PASSENGER SIDE RE0053 AB 42 DIAGNOSTIC CHART WITH TROUBLE CODE CHECK PASSENGER S AIRBAG MODULE Does the airbag warning light 1 Turn the ignition switch OFF disconnect the operate properly battery ground terminal and wait more than 20 seconds 2 Remve the glove box 3 Disconnect the connector AB10 from AB9 4 Connect the connector 1F in the test har ness F to the connector AB9 5 Connect the airbag resistor to connector 3F in the test harness F 6 Connect the battery ground terminal and turn the ignition switch ON CHECK AIRBAG MAIN HARNESS Is the voltage less than 1 V 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the airbag resistor from the con nector 3F in the test harness F 3 Remove the lower cover and disconnec
200. isconnect the connector AB20 from AB19 4 Disconnect the connectors AB17 and AB18 from the airbag control module lt Ref to AB 15 Airbag Control Module gt 5 Connect the connector 11 in the test har ness or 12 to the connector AB17 6 Connect the battery ground terminal and turn the ignition switch ON 7 Measure the voltage between connector 31 in the test harness or 12 and the chassis ground Connector amp terminal 31 No 11 Chassis ground 31 No 13 Chassis ground AB 79 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS AB 80 SEAT BELT SYSTEM te Xaeheral2escrHblioh atra usted ee ena 2 2 Pretensioner 3 Inspection Locations After a Collision 4 PLONE SCA BOM b DCA BEN GENERAL DESCRIPTION SEAT BELT SYSTEM 1 General Description A COMPONENT 1 FRONT SEAT BELT BO0239 1 Adjuster anchor ASSY Tightening torque N m kgf m ft lb 2 Anchor cover T1 7 5 0 76 5 5 3 Outer belt ASSY T2 30 3 1 22 4 Inner belt ASSY T3 53 5 4 39 SB 2 2 REAR SEAT BELT SEDAN 1 3 4 5 Outer seat belt RH Outer seat belt CENTER Outer seat belt LH Inner seat belt RH inner seat belt CENTER GENERAL DESCRIPTION 6 7 9 SEAT BELT SYST
201. ise control command switch 6 Stop and brake switch CC 2 GENERAL DESCRIPTION CRUISE CONTROL SYSTEM B CAUTION e Before disassembling or reassembling parts al ways disconnect the battery ground cable When repairing the radio control module and other parts with memory functions make note of the memory before disconnecting the battery ground cable All memory will be erased e Reassemble the parts in the reverse order of dis assembly unless otherwise indicated e Adjust the parts to specifications specified in this manual Connect the connectors and hoses securely dur ing reassembly e After reassembly ensure functional parts oper ate properly C PREPARATION TOOL Circuit Tester Used for measuring resis tance and voltage CC 3 ACTUATOR CRUISE CONTROL SYSTEM 2 Actuator A REMOVAL CAUTION Be careful not to apply excessive load to the wire cable when adjusting and or installing otherwise the actuator may be deformed or damaged e 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 e When installing cable be careful not to sharply bend or pinch the inner cable other wise the cable may break 1 Disconnect the ground terminal from battery 2 Remove the clip bands from cruise control cable 3 Loosen the nut which secures cruise control ca ble end to throttle cam and then
202. istance 1 Disconnect the ground terminal from battery 2 Remove the lens A and luggage room light mounting screws B Or More than ON 15 08 _ B6M1480A 3 Disconnect the harness connectors and remove the luggage room light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 LUGGAGE ROOM LIGHT BULB 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one LI 27 TRUNK ROOM LIGHT LIGHTING SYSTEM 26 Trunk Room Light A REMOVAL 1 Disconnect the ground terminal from battery 2 Disconnect the harness connectors and remove the trunk room light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one LI 28 GLOVE BOX LIGHT LIGHTING SYSTEM 27 Glove Box Light A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the glove box lt Ref to El 39 REMOV AL Glove Box gt 3 Disconnect the harness connector 4 Remove the glove box light B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification lt Ref to L
203. its harness connector module and or shorts 2 Ground the harness connector terminal with between the key a suitable wire less entry control Connector amp terminal module and horn B176 No 12 chassis ground relay SL 19 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 10 CHECK ROOM LIGHT OPERATION CHECK ROOM LIGHT OPERATION Does the room light illuminate Go to step 2 Make sure the room light illuminates when the room light switch is turned ON CHECK HARNESS BETWEEN ROOM LIGHT Is resistance less than 10 0 The room light AND INTEGRATED MODULE operation circuit is 1 Disconnect the integrated module harness OK connector and room light harness connector 2 Measure the resistance between the inte grated module harness connector terminal and the room light harness connector terminal Connector amp terminal B281 No 5 R52 No 2 11 CHECK OUTPUT SIGNAL TO INTEGRATED MODULE CHECK OUTPUT SIGNAL Is the voltage more than 10 V Go to step 2 Measure the voltage between the keyless entry control module harness connector terminal and chassis ground when UNLOCK DISARM button of transmitter is pressed Connector amp terminal B176 No 9 Chassis ground CHECK OUTPUT SIGNAL Is the voltage more than 10 V to step 3 Measure the voltage between the keyless entry control module harness connector terminal and chassis ground when LOCK ARM button of transmitter is pressed Connector amp terminal
204. jespos 22262128 RE0055 AB 48 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Check Yes Is the voltage more than 10 V Replace the airbag Go to step 2 control module Ref to AB 15 Airbag Control Module CHECK AIRBAG CONTROL MODULE 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the connector AB6 from airbag control module Ref to AB 15 Airbag Control Module 3 Connect the connector 11 in the test har ness or 12 to the connector ABO 4 Connect the battery ground cable and turn the ignition Switch ON 5 Measure the voltage between the connector 21 in the test harness or I2 and the chassis ground Connector amp terminal 21 No 6 Chassis ground CHECK AIRBAG MAIN HARNESS Is the resistance less than 10 1 While checking control module turn the igni Q tion switch OFF and disconnect the battery ground terminal Wait more than 20 seconds before operation 2 Disconnect the airbag connector AB1 from the body harness B31 3 Connect the connector 2M in the test har ness M to the airbag connector AB1 4 Measure the resistance between the con nector 5M in the test harness M and the con nector 21 in the test harness or 12 Connector amp terminal 5M No 2 21 No 6 CHECK AIRBAG MAIN HARNESS Measure the following resistance with the above mentioned condition maintain
205. l e Do not cross piano wires Otherwise they may be cut GW 23 WINDSHIELD GLASS GLASS WINDOWS MIRRORS B INSTALLATION 1 Clean the external circumference of windshield glass with alcohol or white gasoline 2 Remove the adhesive layer on the body using cutter knife to obtain smooth face 2 mm 0 08 in thick CAUTION Be careful not to damage the body and paint surface Adhesive gt a 2mm 0 08 in Glass G5M0553 3 Clean the body with alcohol or white gasoline to remove thoroughly chips dusts and dirts from the body face 4 Place the glass on body 5 Adjust the glass position to make uniform clear ance between body and glass in four corners 6 Bond the matching pins and dam rubber Dam rubber _ LL E 11 0 433 Matching pin Fastener Dam rubber 11 0 433 aes Unit mm in 7 Remove the glass from body 8 Fit the molding mark B to notch A B BO0270 9 Apply the primer to the adhesive layer of glass using sponge 10 Apply the primer to the adhesive layer of body CAUTION e Primer once attached to the painted surface of the body and internal trim is hard to wipe off Mask the circumference of such areas e Let primer dry for about ten minutes before installing the glass Do not touch surface coated with primer Application of primer FB Glass side Body side G5M0495 GW 24 WINDSHIELD GLASS 11 Cut off the cartridge n
206. l 2 SPECIFICATIONS General Description gt 3 If NG replace the bulb with a new one 1 29 GLOVE BOX LIGHT LIGHTING SYSTEM LI 30 WIPER AND WASHER SYSTEMS Oo UNO Oe NS 6 corio ea Gotan enone 2 Wiper and Washer System ira iu dn es reos 5 Combination Switch Wiper cccccececeeseseseeeeseneeeseeeeeeaaueeeueneeneeeseeeeas 7 Wiper Blade ccr 9 Washer Tank and MOO epe hore NE up REM UA 11 Front Wiper PATI sce recae Eoo iia o UMBRA E Nodes 12 Front Wiper Motor and ceisiai vea 13 Front Washer Nozzle Rear VIDOR A sce e o E pe e EUR OP avit c n ventes Rear Wiper enne dic cua ub ora REDE CV ev RED A Rear Washer Nozzle Wiper Control Helay atti vet idu ace nene aeo mo di eoru cid MUN EM et d GENERAL DESCRIPTION WIPER AND WASHER SYSTEMS 1 General Description A SPECIFICATIONS Front wiper mator 2V 72 Wor loss I2 V 42 Worless Pump type Centrifugal Fromwashermotr pg e EN ee l B COMPONENT 1 FRONT WIPER 1 2 i BO0272 1 Wiper rubber 4 Wiper link Tightening torque N m kgf m ft Ib 2 Wiper blade ASSY 5 Wiper motor T1 6 0 0 61 4 4 3 Wiper arm T2 20 2 0 14 5 WW 2 GENERAL DESCRIPTION WIPER AND WASHER SYSTE
207. l main switch 7 Cruise control module 2 Inhibitor switch AT b Clutch switch MT 3 Cruise control command switch 6 Stop and brake switch CC 5 CRUISE CONTROL MODULE I O SIGNAL CRUISE CONTROL SYSTEM DIAGNOSTICS 4 Cruise Control Module I O Signal A ELECTRICAL SPECIFICATION G6M0015 e 0 volt is present when main switch is turned ON e Battery voltage is present when selector lever is other than P or N position 0 volt is present when selector lever is set to P or N position ON and OFF 0 and battery voltage operation is alternately repeated while cruise control is operating e 0 volt is present when main switch is turned OFF ON and OFF 0 and battery voltage operation is alternately repeated while cruise control is operating e 0 volt is present when main switch is turned OFF e Battery voltage is present when command switch is turned to RESUME ACCEL position e O volt is present when command switch is released e Battery voltage is present when command switch is turned to SET COAST position e 0 volt is present when command switch is released e Battery voltage is present when ignition switch is turned ON e 0 volt is present when ignition switch is turned OFF e ON and OFF 0 and battery voltage operation is alternately repeated while cruise control is operating e 0 volt is present when main swi
208. lation C INSPECTION 1 Make sure the rod is not deformed 2 Make sure the lever and rod work smoothly SL 28 FRONT OUTER HANDLE 6 Front Outer Handle A REMOVAL 1 Remove the door trim lt Ref to El 37 REMOV AL Front Door Trim gt 2 Remove the sealing cover lt Ref to EB 14 RE MOVAL Front Sealing Cover gt 3 Remove bolt A 4 Move the front door glass downward Remove the bolt and rod clamp 5 Remove the front outer handle CAUTION Do not use excessive force to remove the door panel This will deform it B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Make sure the rod is not deformed 2 Make sure the lever and rod work smoothly SL 29 SECURITY AND LOCKS FRONT DOOR LATCH ASSEMBLY SECURITY AND LOCKS 7 Front Door Latch Assembly A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the front door trim Ref to El 37 RE MOVAL Front Door Trim gt 3 Remove the sealing cover lt Ref to EB 14 RE MOVAL Front Sealing Cover gt 4 Remove the front inner remote lt Ref to SL 28 REMOVAL Front Inner Remote gt 5 Remove the three screws and bolt ese 6 Disconnect the connector Remove the front door latch assembly B INSTALLATION Install in the reverse order of removal CAUTION Make sure the lock works properly after instal lation C INSPECTION 1 Make sure the rod is not deformed 2 Make sure t
209. lay and Fuse A LOCATION HVAC SYSTEM HEATER VENTILATOR AND B INSPECTION 3 4 Continuity exists 1 2 No continuity While applying battery voltage to the cable be tween 3 and 4 check continuity between 1 and 2 If no continuity exists replace the relay with a new one AC 31 PRESSURE SWITCH DUAL SWITCH HVAC SYSTEM HEATER VENTILATOR AND A C 17 Pressure Switch Dual Switch A INSPECTION 1 Connect the manifold gauge to the service valve on the high pressure side 2 Remove the pressure switch harness connector Using a circuit tester inspect the ON OFF opera tion of the pressure switch Terminal nerin Standard No kPa psi 2 29 1 Turns OFF 800 100 1 406115 1 2 Decreasing to 278129 2 83 0 3 40 3 4 2 Increasing to 287 39 5 2 9 94 os 42 9 6 Decreasing to 2 200 200 22 442 319129 High and low pressure switch AC 32 AIR VENT GRILLE HVAC SYSTEM HEATER VENTILATOR AND A C 18 Air Vent Grille A REMOVAL 1 CENTER GRILLE 1 Disconnect the ground terminal from battery 2 Remove the center console panel A 3 Loosen two screws to remove the center air vent grille B o e 2 SIDE GRILLE 1 Disconnect the ground terminal from battery 2 Remove the heater vent duct lt Ref to AC 35 REMOVAL Heater Vent Duct gt 3 Loos
210. llow Vehicle 58 center 51 Glass attaching hole Right 6 5 mm 60 0 256 in dia Left 6 5 x 10 mm 0 256 x 0 39 in dia 63 55 Rear combination light mounting hole 8 mm 0 31 in dia Symmet 65 rical 56 Bumper attaching hole 7 mm 66 0 28 in dia Symmetrical DATUM POINTS Rear bumper attaching hole 11 mm 0 43 in dia Symmetrical Choke coil harness attaching hole 5 4 mm 0 213 in dia Feeder line fixing hole 7 mm 0 28 in Symmetrical Floor mat clip attaching hole 8 mm 0 31 in dia Bulkhead rear gauge hole 10 mm 0 39 in dia Symmetrical BS 5 BODY STRUCTURE 67 Gusset floor rear side gauge hole 68 69 76 11 5 mm 0 453 in dia Symmet rical Rear skirt inner side gauge hole 10 mm 0 39 in dia Symmetri cal Rear panel reinforcement repair locator hollow Vehicle center Press location hole 15 mm 0 59 in dia Symmetrical DATUM POINTS BODY STRUCTURE 4 UNDERBODY SECTION 81 92 82 90 JA LH ANI ICIS dt AX Ele CIL aud g 81 92 82 90 pee DD Ny UNT 83 84 85 94 86 87 85 83 84 88 88 91 89 93 89 93 BO0407 80 Radiator lower frame gauge hole 85 Transmission mount attaching 90 Strut mount attaching hole 9 5 mm 12 mm 0 47 in dia Symmetri hole 14 mm 0 55 in dia 0 374 in
211. mbly eene enne 17 Trunk Lid Release Handle eere 18 Front Hood Lock nenne 19 Remote Openers eeseeeeenmmHHemneennennnnnnennnnnnnen nennen 20 Ignition Key Lock eene 21 Key Lock Cylinders sssse eene 22 Security Control Module sssseen eee enne 23 Security Horn 24 Security Horn eene enne 25 Interrupt Relay sssssssseenen enne enne ene nennen 26 Keyless Entry Control Module 27 Integrated Module sssssseeenee eee ener 28 Keyless Transmitter ssssssenn eee eene SECURITY AND LOCKS 1 General Description A COMPONENT 1 DOOR LOCK ASSEMBLY 1 2 3 4 5 FRONT A Inner remote ASSY Inner remote cover Bell crank Auto door lock actuator Door latch GENERAL DESCRIPTION 6 7 8 Striker Door outer handle Key cylinder SL 2 T3 14 1 4 10 1 BO0397 Tightening torque N m kgf m ft lb 1 6 4 0 65 4 7 2 7 4 0 75 5 4 GENERAL DESCRIPTION SECURITY AND LOCKS 2 TRUNK LID AND REAR GATE LOCK TRUNK REAR GATE BO0329 1 Key cylinder 5 Rear gate outer handle Tightening torque N m kgf m ft lb 2 Cable 6 Rear gate actuator T1 4 5 0 46 3 3 3 Striker 7 Trunk
212. mended that contour of worktable accommodate internal shape of bumper Bumper placement Set bumper section G5M0164 Remove dust oil etc from areas to be repaired and surrounding areas using a suitable solvent 1 No 900 Precleno white gasoline or alcohol DEE Surface prepara tion Unit mm 20 30 0 79 1 18 1 n Paint surface If nature of damage are 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 5 Cutting 94028 PP base surface G5M0165 Sanding I Grind beveled surface with sand paper 440 to 60 to smooth finish 7 Cleaning Clean the sanded surface with the same solvent as used in Process No 4 Grind the side just opposite the beveled area with sand paper 40 to 60 and clean using a sol vent Temporarily spot weld the side using a PP welding rod and heater gun Welded spot Use heater gun and PP welding rod Temporary welding PP base surface E Beveled section G5M0166 NOTE e Do not melt welding rod until it flows out This results in reduced strength Leave the welded spot unattended until it cools completely El 27 FRONT BUMPER EXTERIOR INTERIOR TRIM Pro cess Process name Job contents No Using a heater gun and PP welding rod weld the beveled spo
213. minal Ref to WI 98 SCHEMATIC Headlight System 2 CLEARANCE LIGHT AND ILLUMINA TION LIGHT Ref to WI 94 SCHEMATIC Clearance Light and Illumination Light System B INSPECTION 1 HEADLIGHT RELAY Measure the headlight relay resistance between terminals when connecting terminal No 4 to battery positive terminal and terminal No 3 to battery ground terminal 1 and Standard pm Less than 12 More than TMA Li 3 FRONT FOG LIGHT SYSTEM LIGHTING SYSTEM 3 Front Fog Light System A SCHEMATIC 1 FRONT FOG LIGHT lt Ref to WI 97 SCHEMATIC Front Fog Light Sys tem gt B INSPECTION 1 FRONT FOG LIGHT SWITCH Measure the front fog light switch resistance Switch position Terminal No Standard More than 1 d5 o mS Less than 1Q 2 FRONT FOG LIGHT RELAY Measure the front fog light relay resistance be tween terminals when connecting terminal No 4 to battery positive terminal and terminal No 3 to bat tery ground terminal Standard m Less than 10 Ne flow More than TMA Li 4 TURN SIGNAL AND HAZARD LIGHT SYSTEM LIGHTING SYSTEM 4 Turn Signal and Hazard Light System A SCHEMATIC 1 TURN SIGNAL LIGHT AND HAZARD LIGHT lt Ref to WI 104 SCHEMATIC Turn Signal Light and Hazard Light System gt B INSPECTION 1 TURN SIGNAL SWITCH lt Ref to LI 9 INSPECTION Combination Switch Light gt 2 HAZARD SWITCH Measure the hazard switch
214. minal and chassis ground when SET COAST switch is pressed and not pressed Connector amp terminal B94 No 10 Chassis ground CHECK RESUME ACCEL SWITCH CIRCUIT Measure voltage between harness connector terminal and chassis ground when RESUME ACCEL switch is pressed and not pressed Connector amp terminal B94 No 9 Chassis ground CHECK CANCEL SWITCH CIRCUIT Measure voltage between harness connector terminal and chassis ground when CANCEL switch is pressed and not pressed Connector amp terminal B94 No 9 Chassis ground B94 No 10 Chassis ground CHECK POWER SUPPLY FOR COMMAND SWITCH Check horn operation Is the voltage O V when RESUME ACCEL switch is not pressed Is the voltage more than 10 V when RESUME ACCEL switch is pressed Is the voltage 0 V when CAN CEL switch is not pressed Is the voltage more than 10 V when CANCEL switch is pressed e Check fuse No 6 in fuse amp relay box e Check horn Does horn sound Go to step 5 e Check harness for open or short between cruise control command switch and fuse amp relay box Replace cruise control command switch CHECK CRUISE CONTROL COMMAND SWITCH Remove and check cruise contro command switch Ref to CC 7 Cruise Control Com mand Switch Check harness between cruise control
215. mirror assembly lt Ref to GW 33 REMOVAL Outer Mirror Assembly gt 4 Remove the front door glass lt Ref to GW 15 REMOVAL Front Door Glass gt 5 Remove the front door regulator and motor lt Ref to GW 19 REMOVAL Front Regulator and Motor Assembly gt 6 Remove the front door latch assembly lt Ref to SL 30 REMOVAL Front Door Latch Assembly gt 7 Remove the front outer handle lt Ref to SL 29 REMOVAL Front Outer Handle gt 8 Remove the front pillar lower trim to disconnect connector from the body harness 9 Put a wooden block on jack and place jack under the door Support the door with a support jack to protect it from damage 10 Remove the checker bolts S5M0183 11 Remove the door side bolts for upper and lower hinges to remove the door G5M0385 CAUTION e During removal and installation of doors do not damage body Doors are heavy Be careful not to drop and damage them B INSTALLATION 1 Install in the reverse order of removal 2 Apply grease to sliding area of the door hinges Refer to COMPONENT of General Description for tightening torque lt Ref to EB 5 FRONT DOOR PANEL General Description gt EB 12 FRONT DOOR PANEL C ADJUSTMENT 1 Using special tool loosen the body side bolts of upper and lower hinges to align the position of front door panel longitudinally and vertically ST 925610000 DOOR HINGE WRENCH 2 Loosen the screw A a
216. moval C INSPECTION Measure the interrupt relay resistance between ter minals indicated in the table below when connect ing terminal No 4 to battery positive terminal and terminal No 1 to battery ground terminal Less than 1 0 More than 1 If NG replace the interrupt relay SL 48 KEYLESS ENTRY CONTROL MODULE SECURITY AND LOCKS 26 Keyless Entry Control Mod ule A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the instrument panel lower cover lt Ref to El 42 REMOVAL instrument Panel Assembly gt 3 Remove the nut then remove the keyless entry control module while disconnecting the connector B INSTALLATION Install in the reverse order of removal SL 49 INTEGRATED MODULE SECURITY AND LOCKS 27 Integrated Module A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the instrument panel lower cover Ref to El 42 REMOVAL Instrument Panel Assembly 3 Remove the nut then remove the integrated module while disconnecting the connector B INSTALLATION Install in the reverse order of removal SL 50 KEYLESS TRANSMITTER SECURITY AND LOCKS 28 Keyless Transmitter A REMOVAL 1 TRANSMITTER BATTERY Remove the battery from the transmitter NOTE To prevent static electricity damage to the transmit ter printed circuit board touch the steel area of building with hand to discharge static electricity car ried on body or
217. mper To avoid damage to the bumper lay the re moved bumper on sheet spread on the floor Do not lay it directly on the floor 1 Disconnect the ground terminal from battery 2 Remove the front grille Ref to El 18 REMOV AL Front Grille 3 Loosen the three clips to remove the head light side cover 4 Pull off the front side of front mud guard to re move the clip 5 Remove clips and pull out bumper slightly EXTERIOR INTEHIOR TRIM 6 Disconnect the fog light connector to remove the bumper 7 Remove the E A FORM from bumper beam CAUTION e E A FORM may easily break Do not apply ex cessive force to it during removal El 23 FRONT BUMPER EXTERIOR INTERIOR TRIM B INSTALLATION CAUTION e Handle the bumper carefully to avoid damage to the bumper face e Do not damage the body during removal or installation of bumper 1 Install in the reverse order of removal 2 Fit the slider A to guide plate B securely Tightening torque Refer to COMPONENT of General Description for tightening torque Ref to El 4 FRONT BUMPER COMPONENT General Descrip tion El 24 FRONT BUMPER EXTERIOR INTERIOR TRIM C REPAIR 1 COATING METHOD FOR PP BUMPER Pro cess Process name Job contents Bumper Set the bumper on paint worktable if required Bumper mounting Use paint worktable conforming to inner shape of bumper when possible Set bumper section G5M0164
218. n ner may be required However adjustment of one sash to the maximum amount and the other to the minimum amount is not permitted Such adjustment may result in application of exces sive load to regulator 11 After adjustments tighten the nuts 12 After adjustment of glass if there is a gap be tween outer lip of gusset and glass surface adjust the gap with adjusting bolt A in lower fitting part of gusset to prevent generation of wind noise 13 During adjustments loosen other three clamp ing bolts 14 After adjustment tighten the bolts and nuts GW 18 coxa das ee ee ee ee ee c IRE FRONT REGULATOR AND MOTOR ASSEMBLY 6 Front Regulator and Motor Assembly A REMOVAL 1 Remove the door glass lt Ref to GW 15 RE MOVAL Front Door Glass gt 2 Loosen the nuts to remove the rear sash 3 Disconnect the motor connector 4 Loosen four bolts and two nuts to remove the regulator assembly BOO091 GLASS WINDOWS MIRRORS B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the front door glass lt Ref to GW 17 AD JUSTMENT Front Door Glass C INSPECTION 1 Make sure that the power window motor rotates properly when the battery voltage is applied to the terminals of motor connector 2 Change the polarity of battery connections to ter minals to ensure that the motor rotates in reverse direction GW 19 i i E REAR DOOR GLASS GLAS
219. n 102 More than 1MQ LI 7 INTERIOR LIGHT SYSTEM LIGHTING SYSTEM 7 Interior Light System A SCHEMATIC 1 INTERIOR LIGHT Ref to WI 101 SCHEMATIC In Compartment Light System gt B INSPECTION 1 DOOR SWITCH Measure the door switch resistance Switch position Standard opened When d 1and 3 dedi More than 1MQ closed 2 REAR GATE LATCH SWITCH Measure the rear gate latch switch resistance Standard When rear gate is Less than 12 opened 1 2 en rear gate IS More than 1MQ closed 3 TRUNK ROOM LIGHT SWITCH Measure the trunk room light switch resistance When trunk lid is te opened When trunk lid i vange SRL ATHE AGS More than 1MQ closed LI 8 COMBINATION SWITCH LIGHT LIGHTING SYSTEM 8 Combination Switch Light A REMOVAL 1 Remove the instrument panel lower cover lt Ref to El 42 REMOVAL Instrument Panel Assembly gt 2 Remove the screws which secure upper column cover to lower column cover 3 Disconnect the connector from combination Switch 4 Remove the screws which secure switch and re move the switch B INSTALLATION Install in the reverse order of removal LI 9 C INSPECTION Measure the combination switch resistance 7 TL ____ 1 8 7 1615431211 17 16 15141312411 10 9 Lighting and turn signal switch connector 211 Parking switch connector
220. n connector lt Ref to AB 15 3l in the test harness or I2 and the chassis Airbag Control Go to step 4 Go to step 5 31 No 2 3H No 5 31 No 4 3H No 6 CHECK AIRBAG MAIN HARNESS AND Is the resistance more than 1 to step 10 Go to step 5 FRONT SUB SENSOR HARNESS RH MO Measure the resistance between connector 31 in the test harness or 12 and the chassis ground i Connector amp terminal 31 No 2 Chassis ground 31 No 4 Chassis ground CHECK AIRBAG MAIN HARNESS Is the resistance less than 10 Go to step 6 Replace the body 1 Disconnect the connector AB15 from Q AB14 and connect the connector 1F in test harness F to the connector AB14 2 Measure the resistance between connector 31 in the test harness or 12 and connector in the test harness F Connector amp terminal 31 No 2 3F No 4 3I No 4 3F No 3 ground Module harness with air CHECK AIRBAG MAIN HARNESS Is the resistance more than 1 Go to step 7 Replace the body Measure the resistance between connector MO harness with air 31 in the test harness or 12 and the chassis bag main harness ground Connector amp terminal 31 No 2 Chassis ground 3I No 4 Chassis ground Is the resistance less than 100 Connector amp terminal bag main harness AB 51 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS eek Ne 7 CH
221. n valve Expansion valve frozen temporarily by moisture e Defective compressor e Replace the compressor Low pressure side is unusually high e Defective expansion valve e Replace the expansion valve Too much refrigerant e Discharge refigerant e Not enough refrigerant e Check for leaks e Clogged expansion valve e Replace the expansion valve e Expansion valve frozen temporarily by e Replace the receiver dryer moisture e Saturated receiver dryer High pressure side is unusually high e Replace the compressor e Check for leaks e Replace the expansion valve High pressure side is unusually low Low pressure side is unusually low AC 15 REFRIGERANT RECOVERY PROCEDURE HVAC SYSTEM HEATER VENTILATOR AND A C 3 Refrigerant Recovery Proce dure A OPERATION CAUTION During operation be sure to wear safety gog gies and protective gloves Connect the refrigerant recovery system with the manifold gauge set to discharge the refrig erant from the A C system and reuse it e When reusing the discharged refrigerant keep service cans on hand Because the dis charge rate with the recovery system is approx 9096 service cans are necessary to charge the refrigerant Follow the detailed operation procedure de scribed in the operation manual attached to the refrigerant recovery system 1 Perform the compressor oil return opera
222. nd tap striker B using plastic hammer to adjust striker to align the position of front door panel vertically and laterally at the rear end CAUTION Do not use impact wrench Welding area on striker nut plate is easily broken B B5M0934A EB 13 EXTERIOR BODY PANELS FRONT SEALING COVER EXTERIOR BODY PANELS 5 Front Sealing Cover A REMOVAL 1 Disconnect the battery ground cable 2 Remove the front door trim Ref to El 37 RE MOVAL Front Door Trim gt 3 Remove the front speaker lt Ref to ET 7 RE MOVAL Front Speaker gt 4 Using a spatula remove the sealer CAUTION e Carefully remove sealer Excessive force will easily break the cover e If cover gets broken replace it with a new one G5M0391 B INSTALLATION 1 Install in the reverse order of removal 2 When replacing sealing cover use the CEME DINE 5430L sealer 3 Press the sealer applied area firmly to prevent any floating on surface Sealer CEMEDINE 5430L or equivalent CAUTION e Apply a uniform bead of sealer e Attach sealing cover keeping it from becom ing wrinkled e Breaks in the bead will allow water leakage and contamination C INSPECTION If the sealing cover is damaged replace it with a new one EB 14 REAR DOOR PANEL 6 Rear Door Panel A REMOVAL CAUTION e During removal and installation of doors do not damage body Doors are heavy Be careful not to drop and
223. nd the spring for rust forma tion and unsmooth movement SL 39 TRUNK LID RELEASE HANDLE SECURITY AND LOCKS 17 Trunk Lid Release Handle A REMOVAL 1 Remove the five clips B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Make sure the cable is not deformed 2 Make sure the lever works smoothly SL 40 FRONT HOOD LOCK ASSEMBLY SECURITY AND LOCKS 18 Front Hood Lock Assembly A REMOVAL 1 Open the hood 2 Remove the bolt Remove the hood lock assem bly 3 Remove the release cable from the lock assem B INSTALLATION Install in the reverse order of removal CAUTION e Apply grease to the parts that rub e Make sure the release cable works properly after installation C ADJUSTMENT Loosen the bolt Adjust the lock assembly while moving it up and down D INSPECTION 1 Check the striker for bending or abnormal wear 2 Check the safety lever for improper movement 3 Check other levers and the spring for rust forma tion and unsmooth movement SL 41 REMOTE OPENERS SECURITY AND LOCKS 19 Remote Openers A REMOVAL 1 HOOD OPENER 1 Remove the release cable from the hood lock 2 Remove the bolt Remove the opener lever aur B5M0751 2 TRUNK LID OPENER 1 Remove the rear seat lt Ref to SE 11 REMOV AL Rear Seat gt 2 Remove the center pillar lower trim and side sill cover on the passenger side Remove the rear
224. nector AB18 6 Measure the resistance between connector 31 in the test harness or I2 and connector 3L in the test harness L Connector amp terminal 31 No 8 3L No 6 31 No 6 3L No 5 CHECK SIDE AIRBAG HARNESS RH Is the resistance more than 1 Measure the resistance of the connector 3l in MO the test harness or 12 Connector amp terminal 31 No 6 No 8 CHECK SIDE AIRBAG HARNESS RH Measure the resistance between connector 31 in the test harness or 12 and the chassis ground Connector amp terminal 31 No 6 Chassis ground 31 No 8 Chassis ground Go to step 3 Replace the body harness with side airbag harness Go to step 4 Replace the body harness with side airbag harness Is the resistance more than 1 MQ Replace the airbag Replace the body control module harness with side lt Ref to AB 15 airbag harness Airbag Control Module AB 73 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS V TROUBLE CODE 62 DIAGNOSIS e Seat belt pretensioner LH circuit is open shorted or shorted to ground e Airbag control module is faulty e Pretensioner is faulty e Pretensioner harness is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the groun
225. nector amp terminal B17 No 3 Engine ground CHECK HARNESS BETWEEN VEHICLE SPEED SENSOR AND ENGINE GROUND 1 Turn the ignition switch to OFF 2 Measure the resistance between the vehicle speed sensor connector B17 and engine ground Connector amp terminal B17 No 2 Engine ground CHECK HARNESS BETWEEN VEHICLE SPEED SENSOR AND COMBINATION METER 1 Disconnect the connector from the combina tion meter 2 Measure the resistance between the vehicle Speed sensor harness connector and combi nation meter harness connector Connector amp terminal B17 No 1 i10 No 2 Check the harness for open or short between the igni tion switch and vehicle speed sen sor Is the resistance less than 10 Go to step 4 Repair the wiring harness Is the resistance less than 10 Replace the vehi Repair the wiring cle speed sensor IDI 6 COMBINATION METER SYSTEM INSTRUMENTATION DRIVER INFO 4 CHECK TRANSMISSION CONTROL MODULE Check Yes Is the voltage less than 1 V Go to step 2 lt more than 4 V CHECK TRANSMISSION CONTROL MOD ULE SIGNAL 1 Set the vehicle on a free roller or lift up the vehicle and support it with safety stands Warning Be careful not to get caught in the running wheels 2 Drive the vehicle faster than 10 km h 6 MPH 3 Measure the voltage betw
226. nemis 17 Outer NEF OR eret enl wed i EE as aa SS aslo pe e Ea usa DE 18 Remote Control Mirror Switch GENERAL DESCRIPTION GLASS WINDOWS MIRRORS 1 General Description A COMPONENT 1 FIXED GLASS SEDAN 2 m Aa 5 CSS n j 3 6 5 K Y 2 BO0391 1 Windshield glass 4 Rearview mirror mount 7 Spring 2 Dam rubber 5 Locate pin 3 Molding 6 Rear window glass GW 2 GENERAL DESCRIPTION GLASS WINDOWS MIRRORS 2 FIXED GLASS WAGON BO0392 1 Windshield glass 4 Rearview mirror mount 7 Rear quarter glass 2 Dam rubber b Locate pin 8 Locate pin 3 Molding 6 Fastener 9 Glass GW 3 GENERAL DESCRIPTION GLASS WINDOWS MIRRORS 3 FRONT DOOR GLASS 00236 1 Glass 5 Motor ASSY Tightening torque N m kgf m ft lb 2 Door sash Front T1 7 4 0 75 5 5 3 Door sash Rear 2 13 7 1 4 10 1 4 Regulator ASSY GW 4 GENERAL DESCRIPTION GLASS WINDOWS MIRRORS 4 REAR DOOR GLASS 1 2 3 4 BO0237 Glass 5 Motor ASSY Tightening torque N m kgf m ft lb Door sash Front Ti 7 4 0 75 5 5 Door sash Rear T2 13 7 1 4 10 1 Regulator ASSY GW 5 GENERAL DESCRIPTION GLASS WINDOWS MIRRORS 5 MIRRORS 1 Outer mirror 3 Mount 5 Mirror 2 Inner rearview mirror 4 Spring GW 6 GENERAL DESCRIPTION GLASS WINDOWS MIRRORS B CAUTION When electrical connectors are di
227. ness connector and remove the tweeter B INSTALLATION install in the reverse order of removal ET 8 REAR SPEAKER ENTERTAINMENT 7 Rear Speaker A REMOVAL 1 Disconnect the battery ground cable 2 Remove the rear door trim Ref to El 38 RE MOVAL Rear Door Trim 3 Remove the rear speaker mounting screws 4 Disconnect the harness connector and remove the rear speaker B INSTALLATION Install in the reverse order of removal ET 9 ANTENNA ENTERTAINMENT 8 Antenna A REMOVAL 1 Remove the mounting screws and detach anten na 2 Disconnect the harness connector B INSTALLATION Install in the reverse order of removal ET 10 CIGARETTE LIGHTER ENTERTAINMENT 9 Cigarette Lighter A REMOVAL 1 Disconnect the battery ground cable 2 Remove the center panel lt Ref to ET 6 RE MOVAL Radio Body gt 3 Disconnect the harness connectors and remove the cigarette lighter B INSTALLATION Install in the reverse order of removal ET 11 CIGARETTE LIGHTER ENTERTAINMENT ET 12 COMMUNICATION SYSTEM 1 General do vo US IER 2 2 Horr Sysler ooi asi Ss 3s Sect UU em 4 Horn Switch GENERAL DESCRIPTION COMMUNICATION SYSTEM 1 General Description A PREPARATION TOOL 1 GENERAL TOOLS TOOL REMARKS
228. nlet air 65 C 149 F e Hot water flow rate 360 2 95 1 US gal 79 2 Imp gal h Air flow rate 280 m 9 888 cu ft h Heat mode FRESH FULL HOT at 12 5 V Heating capacity e Temperature control switch FULL COLD Max air flow rate 450 m 15 892 cu ft h Blower fan speed 4th position Mode selector lever RECIRC Heater core size 163 9 x 200 x 25 0 mm height x length x width 6 45 x 7 87 x 0 984 in Magnet motor 200 W or less at 12 V Blower g motor Fan type and size Sirocco fan type diameter x width 150 x 75 mm 5 91 x 2 95 in AC 2 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND 2 A C SYSTEM Specifications Type of air conditioner Reheat air mix type Cooling capacit g capacity 4 385 kcal h 17 402 BTU h HFC 134a CHsFCF3 0 50 05 kg 0 99 0 11 Ib Vane rotary fix volume CR 14 Compressor Discharge 144 cm 8 79 cu in rev Max permissible speed 7 000 rpm Dry single disc type Power consumption 47 W Magnet clutch Type of belt V Ribbed 4 PK Pulley dia effective dia 125 mm 4 92 in Pulley ratio 1 064 Corrugated fin Sub cool type Core face area 0 21 m 2 26 sq ft Core thickness 16 mm 0 63 in Radiation area 5 34 m 57 5 sq ft internal equalizing Type Single tank Evaporator 255 x 200 x 48 mm Dimensions Wx H x T 10 x 7 87 x 1 89 in Fan type Sirocco fan Blower fan Outer diameter x width Power consumption 150 x 75 mm 5 91 x 2 95 in
229. normal Cruise control module is abnormal Wiring harness opened Motor drive system is abnormal DTC 21 22 24 25 28 35 36 37 Motor clutch drive system is abnormal 38 Motor drive shaft does not engage properly M Trouble of motor Vehicle speed signal changes more than 10 km h 6 MPH within 350 ms Two vehicle speed values stored in cruise control module memory are not the same Two output values stored in cruise control module mem ory are not the same Open wiring harness circuit is detected via control mod ule relay when main switch is ON e Motor output circuit is open or shorted e Motor drive circuit is open or shorted Motor turning speed is low Motor clutch output circuit is open or shorted e Motor clutch drive circuit is open or shorted Motor drive gear engagement is not properly adjusted CC 26 Ref to CC 28 DTC 21 24 25 AND 2A CRUISE CONTROL MODULE BUILT IN RELAY CPU RAM Diagnostics Chart with Diagnostic Trouble Code Ref to CC 30 DTC 22 VEHICLE SPEED SEN SOR Diagnostics Chart with Diagnostic Trouble Code Ref to CC 28 DTC 21 24 25 AND 2A CRUISE CONTROL MODULE BUILT IN RELAY CPU RAM Diagnostics Chart with Diagnostic Trouble Code Ref to CC 28 DTC 21 24 25 AND 2A CRUISE CONTROL MODULE BUILT IN RELAY CPU RAM Diagnostics Chart with Diagnostic Trouble Code Ref to CC 33 DTC 28 WIRING HARNESS OPENED Diagnostics C
230. nstall in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to Ll 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one LI 12 FRONT TURN SIGNAL LIGHT BULB LIGHTING SYSTEM 11 Front Turn Signal Light Bulb A REMOVAL 1 Remove the headlight assembly Ref to LI 10 REMOVAL Headlight Assembly 2 Turn the socket A and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one LI 13 CLEARANCE PARKING LIGHT BULB LIGHTING SYSTEM 12 Clearance Parking Light Bulb A REMOVAL 1 Remove the headlight assembly lt Ref to LI 10 REMOVAL Headlight Assembly gt 2 Turn the socket A and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to LI 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one LI 14 FRONT FOG LIGHT ASSEMBLY LIGHTING SYSTEM 13 Front Fog Light Assembly A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the mounting bolts and then detach the fog light assembly 3 Disconnect the harness c
231. ntrol Module harness Replace the body harness with side airbag harness Finish the diagno sis 2 CHECK POOR CONTACT IN CONECTORS AB6 AB17 and AB18 1 Ensure that the connectors are firmly recon nected 2 Connect the battery ground terminal and turn the ignition switch ON Does the airbag warning light operate properly Replace the airbag control module Ref to AB 15 Airbag Control Module AB 44 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS AB 45 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS H TROUBLE CODE 24 DIAGNOSIS e Airbag control module is faulty e Airbag main harness circuit is open e Fuse No 11 in joint box is blown e Body harness circuit is open CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE 6 1 1518 5 26 2712 2 gt lt lt 4 e e
232. o 3 No 4 CHECK FRONT SUB SENSOR LH Is the resistance more than 1 Finish the diagno Replace the front Measure the resistance between connector MO sis sub sensor LH 3H in the test harness H and the chassis Ref to AB 18 ground Front Sub Sen Yes Connector amp terminal Sor 3H No 3 Chassis ground 3H No 4 Chassis ground AB 56 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS AB 57 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS L TROUBLE CODE 41 DIAGNOSIS e Side airbag harness RH is faulty Side airbag module RH is faulty e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons e When inspecting the side airbag harness disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE SIDE AIRBAG SENSOR RH INFLATOR SIDE RH B5M1105 AB 58 DIAGNOS
233. of removal 2 Operate the wiper once 3 Align he wiper blade to ceramic print point mark A of front window pane B6M1193A WW 12 FRONT WIPER MOTOR AND LINK 7 Front Wiper Motor and Link A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the cowl panel lt Ref to El 33 RE MOVAL Cowl Panel gt 3 Disconnect the connector of motor 4 Loosen the bolts and nuts to remove wiper link B INSTALLATION 1 Connect the battery ground terminal to battery 2 To confirm that the motor is at auto stop position connect the harness to motor and turn the wiper switch ON OFF once 3 Disconnect the ground terminal from battery 4 Tighten the nut where rod A and link plate B is aligned in a straight line 5 Install in the reverse order of removal WIPER AND WASHER SYSTEMS C INSPECTION 1 When the battery is connected to the terminal of connectors confirm that motor operates at low speed 2 When the battery is connected to the terminal of connectors confirm that motor operates at high speed 3 Connect the battery to terminals of connector and remove the terminal connection with motor ro tated at low speed and stop the wiper motor through operation WW 13 FRONT WIPER MOTOR AND LINK WIPER AND WASHER SYSTEMS 4 Connect the battery and confirm that the motor stops at automatic stop position after the motor op erates at low speed again WW 14 F
234. olding the connector A and push it in carefully until a connecting sound is heard CAUTION e Be sure to insert the connector in until it locks Then pull on it gently to make sure that it is locked AB 9 INSPECTION LOCATIONS AFTER A COLLISION AIRBAG SYSTEM 3 Inspection Locations After a Collision A INSPECTION If the vehicle is involved in a collision on any side even if it is a slight collision be sure to check the following system parts 1 AIRBAG MODULE DRIVER 1 Check for the following and replace the dam aged parts with new parts e Airbag module is cracked or deformed e Harness and or connector is cracked deformed or open Lead wire is exposed e The module surface is fouled with grease oil water or cleaning solvent 2 When installing a new driver s airbag module check the following If necessary install a new air bag module and steering wheel The steering wheel is in the way making it diffi ult to install the airbag module e The clearance between the driver s airbag mod ule and steering wheel is not constant When steering wheel deformation in axial and ra dial directions exceed limits Specifications Axial direction play A Less than 6 mm 0 24 in Radial direction play L Less than 17 mm 0 67 in B5M0096A 2 AIRBAG MODULE PASSENGER Check for the following and replace damaged parts with new parts e Airbag module is cracked or deformed e
235. on Meter System A SCHEMATIC 1 COMBINATION METER lt Ref to WI 56 SCHEMATIC Combination Meter gt 2 OUTSIDE TEMPERATURE INDICATOR lt Ref to WI 107 SCHEMATIC Outside Tempera ture Display System gt B INSPECTION CAUTION When measuring the voltage and resistance of the ECM TCM or each sensor use a tapered pin with a diameter of less the an 0 64 mm 0 025 in in order to avoid poor contact Do not insert the pin more than 2 mm 0 08 in 1 SYMPTOM CHART Combination meter assembly does not operate Speedometer does not operate Tachometer does not operate Fuel gauge does not operate Water temperature gauge does not operate Outside temperature indicator does not operate 1 Power supply 2 Ground circuit 1 MT Vehicle speed sensor AT Transmission control module 2 Harness 3 Speedometer 1 Engine control module 2 Harness 3 Tachometer 1 Fuel level sensor 2 Harness 3 Fuel gauge 1 Engine coolant temperature sensor 2 Harness 3 Water temperature gauge 1 Ambient sensor 2 Harness 3 Combination meter IDI 4 Ref to IDI 5 CHECK POWER SUPPLY AND GROUND CIRCUIT INSPECTION Combi nation Meter System gt MT Ref to IDI 6 CHECK VEHICLE SPEED SENSOR INSPECTION Combi nation Meter System AT Ref to IDI 7 CHECK TRANSMIS SION CONTROL MOD ULE INSPECTION Combination Meter System Ref to 101 7 CHECK ENGINE CONTROL MO
236. on with the refrigerant to the compressor 1 Increase the engine to 1 500 rpm 2 Turn ON the A C switch 3 Turn the temperature control switch to MAX COOL 4 Put in RECIRC position 5 Turn the blower control switch to HI 6 Leave in this condition for 10 minutes HVAC SYSTEM HEATER VENTILATOR AND A C B REPLACEMENT NOTE e If a component is replaced add an appropriate amount of compressor oil e When replacing the compressor the new com pressor will already have the specified amount of oil in it Install the new compressor after removing the same amount of oil that is remaining in the com pressor removed AC 21 BLOWER MOTOR UNIT ASSEMBLY HVAC SYSTEM HEATER VENTILATOR AND A C 7 Blower Motor Unit Assembly B INSTALLATION Install in the reverse order of removal A REMOVAL 1 Disconnect the ground terminal from battery C INSPECTION 2 Remove the glove box lt Ref to El 39 REMOV Connect the motor connector terminal 1 from the AL Glove Box gt battery to the positive lead and terminal 2 to the 3 Loosen the nut to remove support beam stay negative lead Make sure the motor runs smoothly 6 Loosen the bolt and nut to remove blower motor unit assembly AC 22 BLOWER RESISTOR HVAC SYSTEM HEATER VENTILATOR AND A C 8 Blower Resistor A REMOVAL 1 Remove the glove box Ref to El 39 REMOV AL Glove Box 2 Disconnect the blower resistor connect
237. oner roll connector control module and the sensor reconnect each part and confirm that the warning light operates properly When inspecting the side airbag harness disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM PRETENSIONER LH le HA JE eNe 18 z s B5M1108 AB 78 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS CHECK SEAT BELT PRETENSIONER Does the airbag warning light Replace the seat Go to step 2 1 Turn the ignition switch OFF disconnect the operate properly belt pre tensioner battery ground terminal and wait more than 20 LH Ref to SB seconds 8 Front Seat 2 Disconnect the connector AB21 from the Belt seat belt pretensioner LH Ref to SB 8 Front Seat Belt 3 Connect the connector 1L in the test har ness L to AB21 4 Connect the airbag resistor to the connector 3L in the test harness L 5 Connect the battery ground terminal and turn the ignition switch ON CHECK SIDE AIRBAG HARNESS LH 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 Is the voltage less than 1 V Replace the airbag Replace the body control module harness with side Ref to AB 15 airbag harness seconds Airbag Control 2 Disconnect the airbag resistor from the test Module harness L 3 D
238. onnector B INSTALLATION Install in the reverse order of removal Li 15 FRONT FOG LIGHT BULB LIGHTING SYSTEM 14 Front Fog Light Bulb A REMOVAL 1 Remove the front fog light assembly Ref to LI 15 REMOVAL Front Fog Light Assembly gt 2 Remove the back cover 3 Remove the spring retainer then detach the fog light bulb B INSTALLATION Install inthe reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to 1 2 SPECIFICATIONS General Description 3 If NG replace the bulb with a new one LI 16 FRONT SIDE MARKER LIGHT ASSEMBLY LIGHTING SYSTEM 15 Front Side Marker Light As sembly A REMOVAL 1 Disconnect the ground terminal from battery 2 Pull out the light from body while pushing it up 3 Disconnect the harness connector and remove the light 4 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to Ll 2 SPECIFICATIONS General Description gt 3 If NG replace the bulb with a new one LI 17 REAR COMBINATION LIGHT ASSEMBLY LIGHTING SYSTEM 16 Rear Combination Light As 3 Remove two bolts sembly A REMOVAL 1 SEDAN 1 Disconnect the ground terminal from battery 2 Remove the clips and then detach the trunk rear trim 4 Remo
239. ontrol Module 1 Check the transmitter battery and function Ref to SL 16 CHECK TRANSMIT TER BATTERY AND FUNCTION INSPECTION Keyless Entry Sys tem The panic alarm does not operate 2 Check the horn operation Ref to SL 19 CHECK HORN OPERATION INSPECTION Key less Entry System 3 Replace the keyless entry control module Ref to SL 49 Keyless Entry Control Module SL 14 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS lt Ref to SL 16 CHECK HORN CHIRP SETTING INSPECTION Keyless Entry System gt lt Ref to SL 16 CHECK TRANSMIT TER BATTERY AND FUNCTION INSPECTION Keyless Entry Sys tem gt lt Ref to SL 19 CHECK KEY WARN ING SWITCH INSPECTION Keyless Entry System gt lt Ref to SL 18 CHECK DOOR SWITCH INSPECTION Keyless Entry System gt lt Ref to SL 19 CHECK HORN OPERATION INSPECTION Key less Entry System gt 6 Replace the keyless entry control module lt Ref to SL 49 Keyless Entry Control Module gt 1 Check the transmitter battery and function lt Ref to SL 16 CHECK TRANSMIT TER BATTERY AND FUNCTION INSPECTION Keyless Entry Sys tem gt lt Ref to SL 20 CHECK ROOM LIGHT OPERATION INSPECTION Keyless Entry System gt lt Ref to SL 19 CHECK KEY WARN ING SWITCH INSPECTION Keyless Entry System gt lt Ref to SL 18 CHECK DOOR SWITCH INSPECTION Keyless Entry System gt lt Ref to SL 20 CHECK OUTPUT SIGNAL T
240. or 3 Loosen two screws to remove the blower resis tor B INSTALLATION Install in the reverse order of removal C INSPECTION Measure the blower resistor resistance Standard Approx 0 51 2 Approx 2 70 0 Approx 1 43 0 If NG replace the blower resistor AC 23 HEATER CORE HVAC SYSTEM HEATER VENTILATOR AND 9 Heater Core A REMOVAL 1 Remove the heater and cooling unit lt Ref to AC 28 REMOVAL Heater and Cooling Unit gt 2 Loosen the screws to remove heater core cover B INSTALLATIO Install in the reverse order of removal AC 24 CONTROL UNIT HVAC SYSTEM HEATER VENTILATOR AND 10 Control Unit 2 Remove the glove box lt Ref to El 39 REMOV AL Glove Box gt A REMOVAL 3 Remove the lower panel lt Ref to El 42 Instru 1 Disconnect the ground terminal from battery ment Panel Assembly gt 4 Remove the control wires 7 Pull out the control unit and disconnect connec tors B INSTALLATION _Install in the reverse order of removal AC 25 COMPRESSOR HVAC SYSTEM HEATER VENTILATOR AND A C 11 Compressor A INSPECTION 1 MAGNETIC CLUTCH CLEARANCE 1 Check the clearance of the entire circumference around the drive plate and pulley Standard 0 45 0 15 mm 0 0177 0 0059 in 2 MAGNETIC CLUTCH OPERATION 1 Disconnect the compressor connector 2 Connect the battery positive terminal to the No 3 terminal of the compre
241. or 31 in the test harness or I2 and the chassis ground Connector amp terminal 31 No 10 Chassis ground 31 No 12 Chassis ground AB 65 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS P TROUBLE CODE 51 DIAGNOSIS e Side airbag sensor RH is faulty e Side airbag harness RH is faulty e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons e When inspecting the side airbag harness disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM AB18 AIRBAG CONTROL MODULE SIDE AIRBAG SENSOR RH INFLATOR SIDE RH T eS Ld He pagan 4 5 1 105 66 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Check Yes CHECK SIDE AIRBAG HARNESS RH Is the resistance less than 10 Go to step 2 1 Turn the ignition switch OFF disconnect the Q battery ground terminal and wait m
242. or windshield glass lt Ref to GW 23 REMOVAL Windshield Glass gt B INSTALLATION 1 Bond the dam rubber and matching pin 14 5 0 571 Matching pin Fastener soos 22 in T 866 Dam rubber Unit mm in 2 Install the glass in the same procedure as for windshield glass lt Ref to GW 24 INSTALLA TION Windshield Glass gt 3 Connect the rear defogger terminals CAUTION When door is opened closed after glass is bonded always lower door glass and then open close door carefully Move vehicle slowly 4 After completion of all work allow the vehicle to stand for about 24 hours NOTE For minimum drying time and time the vehicle must be left standing before driving after bonding follow instructions or instruction manual from the adhe sive manufacturer 5 After curing of adhesive pour the water on exter nal surface of vehicle to check that there are no wa ter leaks CAUTION When a vehicle is returned to the user tell him or her that the vehicle should not be subjected to heavy impact for at least three days GW 28 V EY A Ie hae IE T Sa an TATEA REENT aa a a ee eS Te Sse INNER REARVIEW MIRROR GLASS WINDOWS MIRRORS 13 Inner Rearview Mirror A REMOVAL NOTE The spring cannot be reused Prepare a new s
243. ore than 20 seconds 2 Disconnect the connector AB26 from the seat belt pretensioner RH Ref to SB 8 Front Seat Belt 3 Disconnect the connector AB25 from AB24 4 Disconnect the connector AB18 from the airbag control module Ref to AB 15 Airbag Control Module 5 Connect the connector 11 in the test har ness or l2 to the connector AB18 6 Disconnect the connector AB28 from the side airbag sensor RH and connect the con nector 1G in the test harness G to the con nector AB28 7 Measure the resistance between connector 31 in the test harness or 12 and connector 3G in the test harness G PU Connector amp terminal 31 No 17 3G No 2 3I No 18 3G No 1 31 No 19 3G No 5 31 No 20 3G No 4 CHECK SIDE AIRBAG HARNESS RH Is the resistance more than 1 Replace the side Replace the body Measure the resistance between connector airbag sensor harness with side 31 in the test harness or 12 and the chassis RH Ref to AB lairbag harness ground 16 Side Airbag Connector amp terminal Sensor When 31 No 17 Chassis ground the sensor 31 No 18 Chassis ground replacement is not 31 No 19 Chassis ground OK replace the 31 No 20 Chassis ground airbag control module lt Ref to AB 15 Airbag Replace the body harness with side airbag harness Control Module gt
244. over toward you to re move the upper hook Pull down it to remove the lower hook Remove the inner remote cover B INSTALLATION Install in the reverse order of removal B5M1011 4 Remove the clips of trim panel using clip remov er to remove the trim panel El 38 GLOVE BOX 14 Glove Box A REMOVAL 1 Open the glove box 2 Loosen the screws to remove glove box B INSTALLATION Install in the reverse order of removal El 39 EXTERIOR INTERIOR TRIM ROOF RAIL EXTERIOR INTERIOR TRIM 15 Roof Rail A REMOVAL 1 Remove the roof trim lt Ref to El 50 REMOVAL Roof Trim gt 2 Remove the four mounting nuts and then detach the roof rail carefully B INSTALLATION Install in the reverse order of removal CAUTION Be careful not to scratch the body panels with roof rail stud bolts when removing and install ing them El 40 CONSOLE BOX EXTERIOR INTERIOR TRIM 16 Console Box B INSTALLATION A REMOVAL Install in the reverse order of removal 1 Disconnect the ground terminal from battery 2 Remove the console cover El 41 INSTRUMENT PANEL ASSEMBLY EXTERIOR INTERIOR TRIM 17 Instrument Panel Assembly A REMOVAL WARNING e All airbag system wiring harness and con nectors are colored yellow Do not use electri cal test equipment on these circuits e Be careful not to damage the airbag system harness when servicing the instrument panel 1 Disconnect t
245. ovided Side airbag sensor LH is faulty Side airbag module is inflated Seat belt pretensioner RH circuit is open shorted or shorted to ground e Airbag control module is faulty e Pretensioner is faulty e Pretensioner harness is faulty Seat belt pretensioner LH circuit is open shorted or shorted to ground e Airbag control module is faulty e Pretensioner is faulty e Pretensioner harness is faulty Seat belt pretensioner RH circuit is shorted to power supply Pretensioner is faulty Pretensioner harness is faulty e Airbag control module is faulty Ref to AB 72 TROU BLE CODE 61 Diag nostic Chart with Trouble Code Ref to AB 74 Trouble Code 62 Diagnostic Chart with Trouble Code Ref to AB 76 TROU BLE CODE 65 Diag nostic Chart with Trouble Code AB 33 LIST OF DIAGNOSTIC TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Trouble code Memory Contents of troubles Contents of diagnosis Index No oe LH circuit is shorted to lt Ref to AB 78 TROU Provided e Pretensioner is faulty Pretensioner harness is faulty Trouble Cod e Airbag control module is faulty 34 LIST OF DIAGNOSTIC TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS AB 35 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS 13 Diagnostic Chart
246. ozzle tip and set it in seal ant gun as shown 0 47 0 59 Unit mm in G5M0408 12 Apply the adhesive to the glass end surface as shown 13 Fit the matching pins using suction rubber cup to install windshield glass 14 Lightly press the windshield glass for tight fit 15 Make the adhesive surface flush using spatula CAUTION e When door is opened closed after glass is bonded always lower door glass and then open close it carefully e Move vehicle slowly 16 After completion of all work allow vehicle to stand for about 24 hours NOTE For minimum drying time and time the vehicle must be left standing before driving after bonding follow instructions or instruction manual from the adhe sive manufacturer 17 After curing of adhesive pour water on external surface of vehicle to check that there are no water leaks CAUTION When a vehicle is returned to the user tell him or her that the vehicle should not be subjected to heavy impact for at least three days 18 Install the cowl panel Ref to El 33 INSTAL LATION Cowl Panel GW 25 GLASS WINDOWS MIRRORS eT Be uda a Pia sae ee a eS Ee e ee eS Se c e gt a eS aaa a i i ee oe a ee Ria co a a ee ee ee eee R fn ee REAR GATE GLASS GLASS WINDOWS MIRRORS 10 Rear Gate Glass A REMOVAL 1 Remove the rear wiper motor lt Ref to WW 17 REMOVAL Rear Wiper Motor gt 2
247. per grounding CC 33 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS D DTC 35 AND 36 ACTUATOR MOTOR DIAGNOSIS Open or poor contact of cruise control actuator motor TROUBLE SYMPTOM Cruise control cannot be set Cancelled immediately WIRING DIAGRAM IGNITION SWITCH F B No 18 e e CRUISE CONTROL MAIN SWITCH 25 gt lt 2 T2T8 4T5 Te T7 8 To 121516 poa fopra piens pe rz se 16 20 BO0292 CC 34 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS sep J oa Ye Ne CHECK POWER SUPPLY Is the voltage more than 10 V Go to step 2 Check harness for 1 Turn ignition switch OFF open or short 2 Disconnect harness connector from cruise between cruise control actuator control main 3 Turn ignition switch ON switch and cruise 4 Turn cruise control main switch ON 5 Measure voltage between cruise control actuator harness connector terminal and chas sis ground Terminals B7 No 4 Chassis ground CHECK GROUND CIRCUIT OF ACTUATOR Measure resistance between cruise control actuator harness connector terminal and chas sis ground Terminals B7 No 6 Chassis ground MEASURE RESISTANCE OF ACTUATOR Measure resistance of cruise control actuator contro actuator Is resistance less than 10 Q Go to step 3 Repair harness Go to step 4 Replace cruise
248. pring before removal 1 Turn the mirror base 90 degrees clockwise or counterclockwise to remove it A B5M1059 2 Remove the spring from the mirror base CAUTION Be careful not to damage the mirror surface B INSTALLATION instali in the reverse order of removal C INSPECTION Do not let mirror be damaged Do not let spring deteriorate GW 29 POWER WINDOW CONTROL SWITCH GLASS WINDOWS MIRRORS 14 Power Window Control 2 SUB SWITCH Switch 1 Disconnect the ground terminal from battery 2 Remove the switch panel A REMOVAL 3 Disconnect the connector 1 MAIN SWITCH 1 Disconnect the ground terminal from battery 2 Loosen the screw to remove power window main switch 3 Disconnect the connector B INSTALLATION 1 MAIN SWITCH Install in the reverse order of removal 2 SUB SWITCH Install in the reverse order of removal C INSPECTION 1 MAIN SWITCH Measure switch resistance Driver s switch gc 5 E 1 I3and2 1and UP OFF 1 and 5 less than 1Q 2 and 5 Front passenger s switch Terminal No GW 30 POWER WINDOW CONTROL SWITCH GLASS WINDOWS MIRRORS Rear left switch Switch position Standard UP 10 and 13 9 and 5 less than 10 less than 10 13 and 9 10 and 5 less than 1Q Rear right switch Standard and 16 15 and 5 than 10 16 and 15 16 and 5 5 and 15 13 and 15 16 and 5 less than 1Q
249. r s door Door switch Driver s door 8 INPUT V is present when driver s door is open P gt gt Door unlock switch 11 INPUT 0 V is present when operating the door lock switch Door lock switch 12 INPUT V is present when operating the door lock switch gt Keyless entry contiolmodule Keyless entry controlmedule 20 INPUT Room light B5 OUTPUT d when pressing the transmitter UNLOCK DISARM button Door and rear gate lock actuator B6 OUTPUT eer isis is present when pressing the transmitter LOCK ARM Door and rear gate lock actuator B7 OUTPUT Battery voltage is present when pressing the transmitter UNLOCK DIS Except driver side ARM button two times Door lock actuator Driver side B8 OUTPUT D d when pressing the transmitter UNLOCK DIS O V is constantly present gt gt gt 00 51 13 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS C INSPECTION 1 SYMPTOM CHART Symptom None of the functions of the keyless 1 Check the transmitter battery and function lt Ref to SL 16 CHECK TRANSMIT entry system operate TER BATTERY AND FUNCTION INSPECTION Keyless Entry Sys tem gt 2 Check the fuse lt Ref to SL 17 CHECK FUSE INSPECTION Keyless Entry Sys tem gt 3 Check the keyless entry control module power lt Ref to SL 17 CHECK POWER supply and ground circuit SUPPLY AND GROUND CIRCUIT INSPECTION Keyless Entry Sys tem gt 4 Replace the
250. r trim D 1 Remove the rear seat lt Ref to SE 11 REMOV AL Rear Seat gt 2 Remove the side sill rear cover lt Ref to El 46 REMOVAL Lower Inner Trim gt 3 Remove the rear pillar lower cover A 4 Remove the seatbelt lower anchor bolt and then remove the rear pillar upper trim B El 47 REAR QUARTER TRIM EXTERIOR INTERIOR TRIM B INSTALLATION Install in the reverse order of removal CAUTION Be sure to securely hook pawis of inner trim panel to body flange NOTE When installing the rear quarter upper trim be sure to set the rear mole as shown in the figure Outside ial Inside Weatherstrip B5M0673A El 48 SUN VISOR 21 Sun Visor A REMOVAL Remove the mounting screws then detach the sun visor A hook B and center visor C B INSTALLATION Install in the reverse order of removal EI 49 EXTERIOR INTERIOR TRIM ROOF TRIM EXTERIOR INTERIOR TRIM 22 Roof Trim A REMOVAL CAUTION When removing the clip use great care not to damage the roof trim 1 SEDAN 1 Disconnect the ground terminal from battery 2 Remove the spots light Ref to LI 25 REMOV AL Spot Light 3 Remove the room light Ref to LI 26 REMOV AL Room Light 4 Remove the sun visor and hook on both sides Ref to El 49 REMOVAL Sun Visor 5 Remove the assist grips A B5M1025A 6 Remove the upper inner trim Ref to El 45 RE MOVAL Upper Inn
251. ration supply houses AU ra Electronic leak detector An ELECTRONIC LEAK DETECTOR can be obtained from either a specialty tool supply or an A C equipment supplier G4M0579 Weight scale A WEIGHT SCALE such as an electronic charging scale or a bath room scale with digital display will be needed if a 13 6 kg 30 Ib refrig erant container is used G4M0580 AC 14 REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET HVAC SYSTEM HEATER VENTILATOR AND A C 2 Refrigerant Pressure with Manifold Gauge Set A OPERATION 1 Place the vehicle in the shade and draftless condition 2 Connect the manifold gauge set 3 Open the front windows and close all doors 4 Open the hood 5 Increase the engine to 1 500 rpm 6 Turn ON the A C switch 7 Turn the temperature control switch to MAX COOL 8 Put in RECIRC position 9 Turn the blower control switch to HI 10 Read the gauge Standard Low pressure 127 196 kPa 1 3 2 0 kg cm 18 28 psi High pressure 1 471 1 667 kPa 15 17 kg cm 213 242 psi Ambient temperature 30 35 C 86 95 F B INSPECTION Symptom Probable cause Defective condenser fan motor e Replace the fan motor Clogged condenser fan e Clean the condenser fin Too much refrigerant e Discharge refrigerant Air inside the system e Replace the receiver dryer Defective receiver dryer Defective compressor Not enough refrigerant Clogged expansio
252. re not clogged Make sure the hose is not bent D ADJUSTMENT 1 Turn the wiper switch to OFF position 2 When the vehicle stops adjust the washer injec tion position as shown in the figure Injection position A 39 mm 1 54 in B 72 B6M1200C WW 18 WIPER CONTROL RELAY WIPER AND WASHER SYSTEMS 12 Wiper Control Relay A REMOVAL 1 Disconnect the ground terminal from battery Remove the right quarter lower trim Ref to El 47 REMOVAL Rear Quarter Trim gt 2 Loosen the nut to remove control unit B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Disconnect the connector from the wiper control relay 2 Connect the positive lead from the battery to terminal 8 and the negative lead to terminal 6 Connect the positive lead from the voltmeter to terminal 3 and negative lead to ground 3 Measure the voltage when the wiper relay is op erated 12 V 0 V 9 2 sec B6M1523A If operation is not as specified replace the switch WW 19 WIPER CONTROL RELAY WIPER AND WASHER SYSTEMS WW 20 ENTERTAINMENT CON OAPwAN Page General Description aaa 2 ATL 3 Cigarette SV Sten cen eros da Eine pne cpu ied 5 Radio 6 Front SDOBKO oaadireseur pd rn
253. rear wiper arm 3 Remove the cap A nut B and spacer C from rear wiper shaft 2 Connect the battery to terminal of connector and remove the terminal connections with motor rotat ed and stop the wiper motor through operation B6M1202A 4 Remove the rear gate lower trim lt Ref to El 52 REMOVAL Rear Gate Trim gt 5 Unclip the clip of harness and disconnect con nector of wiper motor 6 Loosen the bolts to remove wiper motor assem bly A 3 Connect the battery and confirm that the motor stops at automatic stop position after the motor op erates at low speed again B INSTALLATION 1 Install in the reverse order of removal 2 Install the rear wiper cushion with the arrow mark facing up as shown in the figure WW 17 i j TA Ert NV E ui UR E T TN SN E Tr E au iy WU I e gee are sep Po REAR WASHER NOZZLE WIPER AND WASHER SYSTEMS 11 Rear Washer Nozzle A REMOVAL 1 Remove the high mount stop light Ref to LI 24 REMOVAL High mounted Stop Light 2 Remove the washer hose from the washer noz zle 3 Open the clips on the underside of the hood with a thin screwdriver or other tool and remove the washer nozzle B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the position of the washer liquid sprayer Ref to WW 18 ADJUSTMENT Rear Washer Nozzle gt C INSPECTION e Make sure the nozzle and hose a
254. remove the cable from throttle cam 4 Remove the actuator attaching bolts 5 Remove the actuator while disconnecting con nector B INSTALLATION Install in the reverse order of removal Tightening torque 7 4 0 75 kgf m 5 4 ft lb NOTE A Must be adjusted when cable end outer is fixed in place so that the gap between throttle cam and lever is 0 1 mm 0 0 04 in Must be attached while throttle cam is being pulled by wire cable B Must be coated evenly on cam end inner con nection C Cover must be inserted securely until tip of ca ble touches cover stopper A B6M1213A C INSPECTION Measure the cruise control actuator resistance B6M1568 If NG replace cruise control actuator CC 4 CRUISE CONTROL MODULE CRUISE CONTROL SYSTEM 3 Cruise Control Module A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the side sill front cover 3 Disconnect the connector from the cruise control module 4 Remove the cruise control module A B INSTALLATION Install is in the reverse order of removal CC 5 CRUISE CONTROL MAIN SWITCH CRUISE CONTROL SYSTEM 4 Cruise Control Main Switch A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the screws and clip from the instrument panel lower cover 3 Remove the instrument panel lower cover 4 Disconnect the connector from the cruise control main switch
255. removing the nut do not drop it into trunk lid e Pay attention to avoid damage during remov al or installation B INSTALLATION 1 Install in the reverse order of removal 2 Clean the mounting surfaces of trunk lid and spoiler before installation El 35 SIDE SILL SPOILER EXTERIOR INTERIOR TRIM 11 Side Sill Spoiler A REMOVAL Remove the clips 1 on front 6 on lower then re move the side sill spoiler B INSTALLATION Install in the reverse order of removal El 36 FRONT DOOR TRIM EXTERIOR INTERIOR TRIM 12 Front Door Trim B INSTALLATION Install in the reverse order of removal A REMOVAL CAUTION Do not apply excessive force to the clip Other wise the clip may be broken 1 Disconnect the ground terminal from battery 2 Pull up the inner remote cover toward you to re move the upper hook Pull down it to remove the lower hook Remove the inner remote cover B5M1011 3 Remove the screw 4 Remove the power window switch assembly and disconnect the harness connector 5 Remove the screw 6 Remove the clips of trim panel using clip remov er to remove the trim panel El 37 REAR DOOR TRIM EXTERIOR INTERIOR TRIM 13 Rear Door Trim 5 Disconnect the power window harness connec tor A REMOVAL CAUTION Do not apply excessive force to the clip Other wise the clip may be broken 1 Disconnect the ground terminal from battery 2 Pull up the inner remote c
256. resistance fal 413 211 8171615 en ee 3 TURN SIGNAL amp HAZARD MODULE Connect the battery and turn signal light bulb to the module as shown in the figure The module is properly functioning if it blinks when power is sup plied to the circuit 1 5 BACK UP LIGHT SYSTEM LIGHTING SYSTEM 5 Back up Light System A SCHEMATIC 1 BACK UP LIGHT lt Ref to WI 93 SCHEMATIC Back up Light Sys tem gt B INSPECTION 1 BACK UP LIGHT SWITCH M T Measure the back up light switch resistance A Non turbo model B Turbo model Standard When shift lever is Turbo model set in reverse 2 and 4 Less than 10 position Non turbo model 1 and2 Other positions More than 1MQ 2 INHIBITOR SWITCH A T Measure the inhibitor switch resistance Switch position Less than 10 More than 1MQ When select lever is set in R posi tion 1 and 2 Other positions STOP LIGHT SYSTEM LIGHTING SYSTEM 6 Stop Light System A SCHEMATIC 1 STOP LIGHT lt Ref to WI 103 SCHEMATIC Stop Light Sys tem gt B INSPECTION 1 STOP LIGHT SWITCH Measure the stop light switch resistance Without cruise control With cruise control 252 B6M1486A Standard Switch position When brake pedal 1 and 2 Without is depressed cruise control When brake pedal 2 and 3 With is released cruise control Less tha
257. resistance less than 1 Measure the resistance between the door lock Q switch terminals when moving the door lock switch to UNLOCK Terminal Driver side No 5 No 8 Passenger side No 5 No 2 Is the resistance less than 1 Q Go to step 4 Replace the door lock switch Check the harness Replace the door for open circuits or lock switch shorts between the integrated module and the door lock switch SL 10 DOOR LOCK CONTROL SYSTEM SECURITY AND LOCKS 5 CHECK DOOR LOCK ACTUATOR AND CIRCUIT CHECK OUTPUT SIGNAL Is the voltage more than 10 V to step 2 Replace the inte Measure the voltage between the harness con grated module nector terminal and chassis ground when mov ing the door lock switch to LOCK Connector amp terminal B281 No 6 Chassis ground CHECK OUTPUT SIGNAL Is the voltage more than 10 V Go to step 3 Replace the inte Measure the voltage between the harness con grated module nector terminal and chassis ground when mov ing the door lock switch to UNLOCK Connector amp terminal B291 No 7 8 Chassis ground CHECK DOOR LOCK ACTUATOR Is the door lock actuator OK Check the harness Replace the door Check the door lock actuator for open circuits or lock actuator Front door lock actuator Ref to SL 31 Front shorts between Door Lock Actuator gt the integrated Rear door lock actuator
258. rminal B94 No 6 Chassis ground CC 15 DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS C CHECK CRUISE CONTROL MAIN SWITCH TROUBLE SYMPTOM 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 condition 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 BATTERY IGNITION SWITCH Es F B No 18 D amp o CRUISE CONTROL MAIN SWITCH CRUISE CONTROL MODULE BO0287 CC 16 DIAGNOSTICS CHART WITH SYMPTOM CHECK CRUISE CONTROL MAIN SWITCH 5 the voltage more than 10 V to step 2 CIRCUIT 1 Disconnect cruise control main switch har ness connector 2 Turn ignition switch ON 3 Measure voltage between harness connec tor terminal and chassis ground Connector amp terminal B161 No 3 Chassis ground CHECK CRUISE CONTROL MAIN SWITCH Is the resistance less than 10 to step CIRCUIT Q 1 Turn ignition switch OFF 2 Disconnect cruise control module harness connector 3 Measure resistance between cruise control module harness connector terminal and cruise control main switch harness connector termi nal Connector amp terminal B94 No 15 B161 No 5 B94
259. rn the ignition switch OFF disconnect the ground cable from battery and wait for more than 20 seconds before starting work 3 Remove the center pillar lower trim Ref to EI 46 REMOVAL Lower Inner Trim 4 Remove the anchor cover Loosen the shoulder anchor bolt and then detach the shoulder anchor from center pillar S5M0234 6 Disconnect the yellow connector of pretensioner harness and remove the outer belt front CAUTION e Do not drop or apply any impact to the pre tensioner Pretensioner and bracket should be treated as an assembly Do not attempt to disassemble it SB 8 FRONT SEAT BELT P E E E E v lc C B INSTALLATION 1 OUTER BELT FRONT Install in the reverse order of removal CAUTION e The parts on right and left are not identical Before installation make sure that the correct part is used e Be careful not to twist the belts during instal lation 2 INNER BELT FRONT Install in the reverse order of removal SEAT BELT SYSTEM C INSPECTION 1 OUTER BELT FRONT Check for the following and replace with new parts if necessary Pretensioner is cracked or deformed Seat belt is slackened bent or frayed Seat belt is abnormally wound or extended 2 INNER BELT FRONT Check for the following and replace with new parts if necessary e Inner belt is deformed or damaged Seat belt buckle is engaged improperly SB 9 REAR SE
260. rness connector 2 Turn ignition switch ON 3 Turn cruise control main switch ON 4 Measure voltage between harness connec tor terminal and chassis ground Connector amp terminal B107 No 2 Chassis ground CHECK CLUTCH SWITCH CIRCUIT 1 Turn cruise control main switch and ignition switch OFF 2 Disconnect stop light switch and brake switch harness connector 3 Measure resistance between clutch switch harness connector terminal and stop light switch and brake switch harness connector ter minal Connector amp terminal B107 No 1 B65 No 4 CHECK CLUTCH SWITCH Remove and check clutch switch lt Ref to CC 9 Clutch Switch gt CC 23 Is the voltage more than 10 V Go to step 2 Is the resistance less than 10 Go to step 3 Is clutch switch OK CRUISE CONTROL SYSTEM DIAGNOSTICS Check harness for open or short between clutch switch and cruise control module Repair harness Clutch switch cir Replace clutch cuit is OK switch DIAGNOSTICS CHART WITH SYMPTOM CRUISE CONTROL SYSTEM DIAGNOSTICS G CHECK INHIBITOR SWITCH AT TROUBLE SYMPTOM Cruise control cannot be set WIRING DIAGRAM CRUISE CONTROL MODULE INTERRUPT RELAY SHORT CONNECTOR WSI WITH SECURITY SYSTEM COS WITHOUT SECURITY SYSTEM N STARTER MOTOR INHIBITOR SWITCH AT paene HEHHEE 2 3 HE 7 8 91 112 BO0290 CC 24 DIAGNOSTICS CHART WITH SYMPTOM CRUISE C
261. rol Module 4 Connect the connector 11 in the test har ness or 2 to the connector AB18 5 Measure the resistance between connector 3l in the test harness or 12 and connector 3F in the test harness F Connector amp terminal 31 No 7 No 4 31 No 9 3F No 3 CHECK SIDE AIRBAG HARNESS RH Measure the resistance of the connector 3l in the test harness or 12 Connector amp terminal 31 No 7 No 9 CHECK SIDE AIRBAG HARNESS RH Measure the resistance of the connector the test harness _ Connector amp terminal 3F No 3 No 4 CHECK SIDE AIRBAG HARNESS RH Measure the resistance between connector SF in the test harness F and the chassis ground Connector amp terminal 3F No 3 Chassis ground 3F No 4 Chassis ground CHECK SIDE AIRBAG HARNESS RH Measure the resistance between connector 31 in the test harness or I2 and the chassis ground Connector amp terminal 31 No 7 Chassis ground 31 No 9 Chassis ground Is the resistance more than 1 MQ Is the resistance more 1MQ Is the resistance more than 1 MQ Is the resistance more than 1 Replace the body harness with side airbag harness AB 59 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS M TROUBLE CODE 42 DIAGNOSIS e Side airbag harness
262. rol is canceled and memorized cruise speed is also canceled Once the cruise control is canceled the cruise control cannot be set until the ignition switch and cruise con trol main switch turns OFF and then turns ON again NOTE Check the input output signal and vehicle speed signal with select monitor When the signals are in good condition failure is in cruise control module Check power supply and ground conditions of cruise control module CC 28 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS CC 29 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS B DTC 22 VEHICLE SPEED SENSOR DIAGNOSIS Disconnection or short circuit of vehicle speed sensor system TROUBLE SYMPTOM Cruise control cannot be set Cancelled immediately WIRING DIAGRAM IGNITION SWITCH TRANSMISSION CONTROL MODULE lt TURBO MODEL NON TURBO MODEL Q AT MODEL MT MODEL CRUISE CONTROL MODULE A L 112131 CC 30 om F B No 18 a 4 19 20 21 VEHICLE SPEED SENSOR MT D2 AS SMJ IE E ale amp lt 5 99 Ol 662 2 J2 BBE gt BOO0291 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS Chek Yes No CHECK TRANSMISSION TYPE Is the transmi
263. rom getting wrinkled 2 SEDAN Assemble in the reverse order of disassembly NOTE Do not contaminate or damage the cover While installing the hog rings prevent the seat from getting wrinkled SE 13 REAR SEAT SEATS i me eee SE 14 SECURITY AND LOCKS Page 1 General Description sse e Hee 2 2 Door Lock Control System 8 3 Keyless Entry 12 4 Security System 0 0 eee cecne ener eeeeeeeee terre eee nennen nennen 21 5 Front Inner Remote ssssssssssseeennmn nenne nen nennen 28 6 Front Outer Handle esses ene nennen nnne hne 29 7 Front Door Latch Assembly eee HH 30 8 Front Door Lock Actuator essen nme 31 9 Rear Inner Remote esses nennen nennen en nne nnne nnne nnne 32 10 Rear Outer 33 11 Rear Door Latch Assembly seem HH Henn 34 12 Rear Door Lock een nennen 35 13 Rear Gate Outer Handle eene 36 14 Rear Gate Latch Assembly enne 37 15 Rear Gate Latch Lock 38 16 Trunk Lid Lock Asse
264. rror System A SCHEMATIC lt Ref to WI 118 Remote Controlled Rearview Mir ror System gt GW 13 REMOTE CONTROL MIRROR SYSTEM GLASS WINDOWS MIRRORS B INSPECTION 1 Fuse F B No 1 F B No 4 F B No 19 All function does not operate 2 Mirror switch 3 Wire harness 1 Mirror switch One side of the mirror motor does not operate 2 Mirror motor 3 Wire harness 1 Mirror switch Mirror heater does not operate 2 Mirror heater 3 Wire harness GW 14 FRONT DOOR GLASS 5 Front Door Glass A REMOVAL 1 Remove the front door trim lt Ref to El 37 RE MOVAL Front Door Trim gt 2 Remove the sealing cover lt Ref to EB 14 RE MOVAL Front Sealing Cover 3 Remove the outer mirror assembly lt Ref to GW 33 REMOVAL Outer Mirror Assembly gt 4 Remove the gusset GLASS WINDOWS MIRRORS 6 Remove the rear end of door weather strip and weather strip outer 7 Operate the power window switch to move glass to position shown in the figure and then remove the two nuts from the service holes CAUTION e Do not turn regulator in the closing direction after removal of the glass Otherwise gear may be disengaged e Avoid impact and damage to the glass GW 15 FRONT DOOR GLASS GLASS WINDOWS MIRRORS B INSTALLATION 1 Install in the reverse order of removal CAUTION Make sure that glass stay is placed securely in sash 2 Adjust the front door glass
265. s CHECK POWER SUPPLY FOR SECURITY 15 the voltage more than 10 V Go to step 3 Check the harness CONTROL MODULE for open circuits 1 Turn the parking switch OFF and shorts 2 Disconnect the security control module har between the secu ness connector rity control module 3 Measure the voltage between the security and the fuse control module harness connector terminal and chassis ground Connector amp terminal B93 No 11 chassis ground CHECK HARNESS BETWEEN SECURITY Is the resistance less than 10 Replace the secu Check the harness CONTROL MODULE AND FUSE BOX Q rity control mod for open circuits 1 Disconnect the fuse box harness connector ule and shorts B152 between the secu 2 Measure the resistance between the security rity control module control module harness connector terminal and the fuse and fuse box harness connector terminal Connector amp terminal B93 No 12 B152 No 11 10 CHECK INTERRUPT RELAY CIRCUIT Yes CHECK INTERRUPT RELAY Is the interrupt relay OK Go to step 2 Replace the inter Remove and check the interrupt relay Ref to rupt relay SL 48 Interrupt Relay CHECK POWER SUPPLY FOR INTERRUPT Is the voltage more than 10 V Go to step Check the harness RELAY when the ignition switch is for open circuits Measure the voltage between the interrupt turned to START and shorts relay harness connector terminal and chassis between the inter ground rupt relay and ign
266. s properly When inspecting the airbag main harness disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE STEERING ROLL CONNECTOR INFLATOR DRIVER SIDE YELLOW YELLOW ee Bag 1 2 3 7 8 9 10 11121314 151617 B5M1098 AB 40 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Check Yes CHECK DRIVER S AIRBAG MODULE Does the airbag warning light Replace the Go to step 2 1 Turn the ignition switch OFF disconnect the operate properly driver s airbag battery ground terminal and wait more than 20 module Ref to seconds AB 12 Driver s 2 Remove the driver s airbag module Ref to Airbag Module AB 12 Driver s Airbag Module 3 Connect the connector AB7 to connector 1F in the test harness F 4 Connect the airbag resistor to connector 3F in the test harness F 5 Connect the battery ground terminal and turn the ignition switch ON CHECK ROLL CONNECTOR Does the airbag warning light Replace the roll Go to step 3 connector Hef to AB 17 Roll Connector 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the test harness F from the con nector AB7 3 Remove the lower cover panel and discon nect the connector AB3 from AB8 4 Conn
267. s shorted to the power supply Pretensioner is faulty Pretensioner harness is faulty Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the side airbag harness disconnect the side airbag module connector and seat belt pretensioner connector for the safety reasons WIRING DIAGRAM AB18 AIRBAG CONTROL MODULE PRETENSIONER RH 3 B5M1109 AB 76 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS check w M _ CHECK SEAT BELT PRETENSIONER Does the airbag warning light Replace the seat Go to step 2 1 Turn the ignition switch OFF disconnect the operate properly belt pretensioner battery ground terminal and wait more than 20 RH lt Ref to SB seconds 8 Front Seat 2 Disconnect the connector AB26 from the Belt seat belt pretensioner RH Ref to SB 8 Front Seat Belt 3 Connect the connector 1L in the test har ness L to AB26 4 Connect the airbag resistor to the connector 3L in the test harness L 5 Connect the battery ground terminal and turn the ignition switch ON CHECK SIDE AIRBAG HARNESS RH 1
268. sconnected al ways conduct an operational check after connect ing them again e Avoid impact and damage to the glass i p k f i i f PT nr GW 7 ee E a o EEE A E 4 GENERAL DESCRIPTION GLASS WINDOWS MIRRORS C PREPARATION TOOL Windshield Knife GW 8 POWER WINDOW SYSTEM GLASS WINDOWS MIRRORS 2 Power Window System A SCHEMATIC lt Ref to WI 109 Power Window System gt GW 9 POWER WINDOW SYSTEM GLASS WINDOWS MIRRORS B INSPECTION 1 Fuse SBF 6 2 Power window circuit breaker 3 Power window relay 4 Wire harness 1 Power window main switch 2 Power window sub switch 3 Power window motor 4 Wire harness Window Lock does not operate 1 Power window main switch All power windows does not operate One window does not operate GW 10 REAR WINDOW DEFOGGER SYSTEM GLASS WINDOWS MIRRORS 3 Rear Window Defogger System A SCHEMATIC lt Ref to WI 117 Rear Window Defogger System gt GW 11 REAR WINDOW DEFOGGER SYSTEM GLASS WINDOWS MIRRORS B INSPECTION 1 Fuse M B No 1 F B No 11 2 Rear defogger relay 3 Rear defogger timer 4 Defogger switch 5 Rear defogger condenser 6 Deffogger wire 7 Wire harness Rear window defogger does not operate GW 12 REMOTE CONTROL MIRROR SYSTEM GLASS WINDOWS MIRRORS 4 Remote Control Mi
269. scosity 10 13 sec 20 C 68 F e Film thickness 15 20u e Spraying pressure 245 343 kPa 2 5 3 5 kg cm 36 50 psi Dry at normal temperature 10 min or more at 20 C 68 F In half dried condition avoid dust dirt Apply a clear coat to parts with top coat paint 1 three times at 5 7 minutes intervals e Paint in use Metallic paint Hardener PB Thinner T 301 e Mixing ratio Clear vs hardener 6 1 e Viscosity 14 16 sec 20 C 68 F e Film thickness 25 30u 10 11 El 25 FRONT BUMPER EXTERIOR INTERIOR TRIM 2 REPAIR INSTRUCTIONS FOR COLORED PP BUMPER NOTE All PP bumpers are provided with a grained surface and if the surface is damaged it cannot normally be re stored to its former condition Damage limited to shallow scratches that cause only a change in the lustre 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 ona classification of the extent of damage e Minor damage causing only a change in the lustre of the bumper due to a light touch Almost restorable Pro cess Process name Job contents No Clean the area to be repaired using water Grind the repairing area with 500 sand paper in a feathering motion Repeatedly apply wax to the affected area using a soft cloth such
270. screw hole B6M1389A 3 Install the security control module 4 Perform the impact sensitivity test SL 45 SECURITY HORN SECURITY AND LOCKS 23 Security Horn A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the nuts and then detach the security horn while disconnecting the connector B INSTALLATION Install in the reverse order of removal C INSPECTION Connect the battery to the security horn terminal and case ground and make sure the horn sounds properly If NG replace the security horn SL 46 SECURITY HORN RELAY SECURITY AND LOCKS 24 Security Horn Relay A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the mounting bolt and detach the secu rity horn relay near the fuse box Install in the reverse order of removal C INSPECTION Measure the security horn relay resistance be tween terminals indicated in the table below when connecting terminal No 4 to battery positive termi nal and terminal No 1 to battery ground terminal Current Terminal No Standard Flow Less than 1 Q 3 No flow Aang More than 1 MQ B6M1391 If NG replace the security horn relay SL 47 INTERRUPT RELAY SECURITY AND LOCKS 25 Interrupt Relay A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the mounting nuts and detach the inter rupt relay near the fuse box B INSTALLATION install in the reverse order of re
271. sealing cover lt Ref to EB 17 RE MOVAL Rear Sealing Cover gt 3 Remove the rear inner remote lt Ref to SL 32 REMOVAL Rear Inner Remote gt 4 Remove the rear door latch assembly lt Ref to SL 34 REMOVAL Rear Door Latch Assembly gt 5 Loosen two bolts and nut to remove the rear out er handle 7 Fel xo wh Qa oon 8 BOO111 CAUTION Do not use excessive force to remove the door panel This will deform it B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Make sure the rod is not deformed 2 Make sure the lever and rod work smoothly SL 33 REAR DOOR LATCH ASSEMBLY SECURITY AND LOCKS 11 Rear Door Latch Assembly A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the rear door trim lt Ref to El 38 RE MOVAL Rear Door Trim gt 3 Remove the sealing cover lt Ref to EB 17 RE MOVAL Rear Sealing Cover gt 4 Remove the rear inner remote lt Ref to SL 32 REMOVAL Rear Inner Remote gt 5 Remove the three screws and bolt 6 Disconnect the connector and then remove the rear door latch assembly B INSTALLATION Install in the reverse order of removal CAUTION Make sure the lock works properly after instal lation C INSPECTION 1 Make sure the rod is not deformed 2 Make sure the lever and rod work smoothly SL 34 REAR DOOR LOCK ACTUATOR SECURITY AND LOCKS 12 Re
272. side bracket 8 Bumper back beam 95 9 7 70 EI 5 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 6 MUD GUARD 1 Mud guard 3 Sub frame cover 5 Mud guard plate 2 Clip 4 Brake duct plate 7 COWL PANEL 1 Cowl panel 3 Protector 2 Cowl side panel 4 Seal El 6 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 8 ROOF SPOILER BO0298 1 Roof spoiler 3 Clip Tightening torque N m kgf m ft lb 2 Cap 7 35 0 749 5 42 9 REAR SPOILER BO0299 1 Rear spoiler 4 Grommet Tightening torque N m kgf m ft lb 2 Protector b Seal only RH side T 7 4 0 75 5 46 3 Clip 6 High mount stop lamp El 7 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 10 SIDE SILL SPOILER 1 Side sill spoiler 3 Protector 5 Clip 2 cover 4 Rivet clip 6 Spoiler clip EI 8 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 11 DOOR TRIM 5 BO0253 1 Gusset cover 4 Clip 7 Lower trim 2 Bracket b Trim panel 3 Weatherstrip upper 6 Power window switch cover EI 9 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 12 ROOF RAIL BOO0301 1 Roof rail Tightening torque N m kgf m ft lb 7 4 0 75 5 46 El 10 gt N 00 T i unm umm Uam Gam 13 CONSOLE BOX GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM Console cover Cup holder Bracket Strip Upper lid Lid hinge m
273. ssion type MT Connector amp terminal B17 3 Chassis ground CHECK HARNESS BETWEEN CRUISE CON TROL MODULE AND VEHICLE SPEED SEN SOR 1 Turn ignition switch to OFF 2 Disconnect harness connector from cruise control module 3 Measure resistance between vehicle speed sensor harness connector terminal and cruise contro module harness connector terminal Connector amp terminal B17 No 1 B94 No 19 CHECK HARNESS BETWEEN VEHICLE SPEED SENSOR AND ENGINE GROUND Measure resistance between vehicle speed sensor harness connector terminal and engine ground Connector amp terminal B17 No 2 Engine ground CHECK VEHICLE SPEED SENSOR Is the voltage less than 1V 1 Connect harness connector to vehicle speed lt more than 4 V Sensor 2 Set the vehicle on free roller or lift up the vehicle and support with safety stands Warning Be careful not to be caught up by the run ning wheels 3 Drive the vehicle at speed greater than 20 km h 12 MPH 4 Measure voltage between cruise control module harness connector terminal and chas sis ground Connector amp terminal B94 No 19 Chassis ground CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V Go to step 3 Check harness for AND VEHICLE SPEED SENSOR open or short Is the resistance less than 10 Go to step 4 1 Disconnect harness connector from vehicle between igni
274. ssor connector Ground the negative terminal to the body BIER E cm mun 3 Make sure the magnet clutch engages If NG replace the compressor B REMOVAL 1 Perform the compressor oil return operation Ref to AC 21 OPERATION Compressor Oil 2 Turn A C switch OFF and stop the engine 3 Using refrigerant recovery system discharge re frigerant Ref to AC 16 OPERATION Refriger ant Recovery Procedure 4 Disconnect the ground terminal from battery 5 Remove the V belt Ref to ME SOHC 43 RE MOVAL V belt or Ref to ME DOHC TURBO 44 REMOVAL V belt gt 6 Remove the generator lt Ref to SC 13 RE MOVAL Generator gt 7 Remove the low pressure hose and high pres sure hose me e A A it S Pa T3 oO 8 Disconnect the compressor harness from body harness 9 Loosen the bolts to remove compressor bracket 10 Remove the bolts and then separate compres sor and bracket C INSTALLATION 1 Install in the reverse order of removal 2 Replace the O rings on low high pressure hos es with new ones then apply compressor oil 3 When replacing the compressor adjust amount of compressor oil lt Ref to AC 21 OPERATION Compressor Oil 4 Charge refrigerant Ref to AC 17 OPEHRA TION Refrigerant Charging Procedure AC 26 CONDENSER 12 Condenser A REMOVAL 1 Using the refrigerant recovery system discharge refrigerant lt Ref to A
275. st striker to align the position of front door panel vertically and laterally at the rear end CAUTION Do not use an impact wrench The welding area on the striker nut plate is easily broken B B5M0934A EB 16 REAR SEALING COVER 7 Rear Sealing Cover A REMOVAL 1 Disconnect the battery ground cable 2 Remove the rear door trim lt Ref to El 38 RE MOVAL Rear Door Trim gt 3 Remove the rear speaker lt Ref to ET 9 RE MOVAL Rear Speaker gt 4 Using a spatula remove the sealer CAUTION e Carefully remove sealer Excessive force will easily break the cover e If cover gets broken replace it with a new one B INSTALLATION 1 Install in the reverse order of removal 2 When replacing sealing cover use the CEME DINE 5430L sealer 3 Press the sealer applied area firmly to prevent any floating on surface Sealer CEMEDINE 5430L or equivalent CAUTION e Apply an uniform bead of sealer e Attach sealing cover keeping it from becom ing wrinkled Breaks in the bead will allow water leakage and contamination C INSPECTION If the sealing cover gets damaged replace it with a new one EB 17 EXTERIOR BODY PANELS TRUNK LID PANEL EXTERIOR BODY PANELS 8 Trunk Lid Panel A REMOVAL 1 TRUNK LID 1 Open the trunk lid 2 Remove the trunk lid release handle lt Ref to gt 3 Loosen the trunk lid mounting bolts to remove trunk lid from
276. step 3 CHECK AIRBAG WARNING LIGHT CIRCUIT 15 the airbag warning light Go to step 4 Replace the airbag IN COMBINATION METER warning light bulb 1 Turn the ignition switch OFF disconnect the or combination battery ground terminal and wait more than 20 meter printed cir seconds cuit Ref to IDI 2 Disconnect the connector AB1 from B31 11 Combination 3 Connect the battery ground terminal and Meter Assembly turn the ignition switch ON CHECK AIRBAG MAIN HARNESS Is the airbag warning light Replace the airbag Replace the body 1 Turn the ignition switch OFF disconnect the jturned on control module harness with air battery ground terminal and wait more than 20 Ref to AB 15 bag main harness seconds Airbag Control 2 Connect the connector AB1 to B31 Module 3 Disconnect the connector AB6 from the air bag control module Ref to AB 15 Airbag Control Module 4 Connect the battery ground terminal and turn the ignition switch ON AB 31 LIST OF DIAGNOSTIC TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS 12 List of Diagnostic Trouble Code A LIST Trouble code Memory Contents of troubles Contents of diagnosis e Airbag main harness circuit is open shorted or shorted to ground e Airbag module harness driver circuit is open Ref to AB 36 TROU T Provided shorted or shorted to ground BLE CODE 11 Diag e Roll connector circuit is open shorted or shorted nostic Chart with to ground
277. t close door raise glass until positional relationship between glass and weatherstrip becomes as shown And secure the glass so that the upper stopper lightly touches the glass holder 2 3 0 079 0 118 T 39 6 0 236 Unit mm in GW 17 FRONT DOOR GLASS GLASS WINDOWS MIRRORS For preventing wind noise adjust the glass at the position where tip of gusset is raised up a little A 0 1 5 mm 0 0 059 in 8 After stabilizer adjustment carry out glass crimp adjustment First visually ensure positional rela tionship between retainer amp molding and glass of the roof side and then begin with rear sash adjust ment Adjust two adjusting bolts alternately step by step to obtain dimensions shown below cross sec tion A NOTE If two nuts are loosened at the same time the sash moves back and forth Therefore when one nut is adjusted secure the other 9 Make the same adjustment of two adjusting bolts of rear sash 2 3 0 079 0 118 A GS S 6 0 236 Unit mm in CAUTION Do not tilt sash bracket to inner panel during adjustment Otherwise smooth regulator opera tion cannot be achieved Adjust a line parallel Sash nner panel S5M0201A 10 Make adjustment of front sash in the same manner as that of rear sash CAUTION Although front and rear sashes must as a rule be adjusted in the same manner in some door installation the adjustment in a different ma
278. t Failure A AIRBAG WARNING LIGHT REMAINS ON DIAGNOSIS e Airbag warning light unit is faulty e Airbag control module to airbag warning light circuit is shorted or open e Grounding circuit is faulty e Airbag control module is faulty AB1 and B31 are not connected properly e ABO is not connected properly to airbag control module CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly e When inspecting the airbag main harness disconnect the airbag module connector of the driver and passenger seats for safety reasons AB 27 AIRBAG WARNING LIGHT FAILURE AIRBAG SYSTEM DIAGNOSTICS WIRING DIAGRAM AIRBAG INDICATOR LIGHT VY IN S AIRBAG A ad a ea w 11213 4 516 7 8 9 10 CHECK POOR CONTACT IN CONNECTORS 15 the poor contact in connec tors AB1 and B31 AB1 AND B31 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Remove the side sill cover Driver s side 3 Confirm that firm contact is secured between connectors AB1 and B31 BATTERY AIRBAG CONTROL MODULE 9 1011112113114 i27 26 29 30
279. t the connector AB3 from AB8 4 Disconnect the connector AB6 from the air bag control module and connect the connector 11 in the test harness 1 or I2 Ref to AB 15 Airbag Control Module gt 5 Measure the voltage between connector 21 in the test harness or I2 and the chassis ground Connector amp terminal 21 No 2 Chassis ground 21 No 5 Chassis ground E TROUBLE CODE 21 DIAGNOSIS e Airbag control module is faulty CAUTION e Before diagnosing the airbag system be sure to turn the ignition switch OFF disconnect the ground terminal from the battery and wait more than 20 seconds before starting to work e Before replacing the airbag module seat belt pretensioner roll connector control module and sensor reconnect each part and confirm that the warning light operates properly AIRBAG SYSTEM DIAGNOSTICS Replace the pas Go to step 2 senger airbag module Ref to AB 13 Passen ger s Airbag Mod ule Replace the airbag Replace the body control module harness with air Ref to AB 15 bag main harness Airbag Control Module CHECK IF TROUBLE CODE 21 IS INDICAT 15 the airbag warning light trou Replace the airbag Perform clear ED ble code 21 indicated Read Diagnostic Trouble Code Ref to AB 24 Read Diagnostic Trouble Code control module memory Ref to Ref to AB 15 AB 26 Clear Airbag Control Memory Mode Module AB 43 DI
280. t turn on for more than two minutes NOTE Before checking the headlight aiming be sure of the following The area around the headlight has not sustained any accident damage or other type of deformation Vehicle is parked on level ground The inflation pressure of tires is correct e Vehicle s fuel tank is fully filled Bounce the vehicle several times to normalize the suspension e Make certain that someone is seated in the driv er s seat Turn the headlight on and then adjust the low beam pattern to the following positions on the screen NOTE Adjust the headlight aiming by turning the adjusting screw A LI 10 HEADLIGHT ASSEMBLY LIGHTING SYSTEM 3 m 10 ft H mm in Wagon h mm in at 3 m 10 ft TS WRX 620 24 41 630 24 80 21 0 83 LI 11 HEADLIGHT BULB LIGHTING SYSTEM 10 Headlight Bulb A REMOVAL CAUTION Because the tungsten halogen bulb operates at a high temperature dirt and oil on the bulb surface reduces the bulb s service life Hold the flange portion when replacing the bulb Never touch the glass portion e Do not leave the headlight without a bulb for a long time Dust moisture etc entering the headlight may affect its the performance 1 Disconnect the ground terminal from battery 2 Remove the duct A when right side headlight is removed 3 Disconnect the harness connector 4 Remove the cap A B INSTALLATION I
281. t while melting the rod and dam aged area Welding rod Welding Melt hatched Section area G5M0167 NOTE e Melt the sections indicated by hatched area Do not melt the welding rod until it flows out in order to provide strength e Always keep the heater gun 1 to 2 cm 0 4 to 0 8 in away from the welding spot Leave the welded spot unattended until it cools completely 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 Sanding 11 UD K G5M0168 Sand the welded spot smooth with 240 sand paper Maskin Mask the black substrate section using masking tape 9 Recommended masking tape Nichiban No 533 equivalent Sand Completely clean the entire coated area using solvent similar to that used in Process No 4 degreasing Apply a coat of primer to the repaired surface and its surrounding areas Mask these areas if nec essary 13 Primer coating eee primer Mp 364 PP Primer Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa 2 5 to 3 5 kg cm 36 to 50 psi with a spray gun 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
282. tch gt B INSTALLATION Installation is in the reverse order of removal INSPECTION Measure the inhibitor switch resistance 6 5 413 2 1 121110 9 817 xd e Selector lever Terminal No Standard position Less than 19 7 and 12 Less than 10 More than 1MQ If NG replace the inhibitor switch Except P and N CC 10 CRUISE CONTROL SYSTEM DIAGNOSTICS 12 DIAGNOSUC PIOCOQUEGO ect Eo rro 2 2 General DescapliOD ene demas 3 3 Electrical Components LOoCallOn oic ripae exte nain 5 4 Cruise Control Module VO Signalisten oa 6 5 Subarg Select Monito odo ote ava aure bn REM pads 9 6 Diagnostics Chart with Symptom cese 11 7 List of Diagnostic Trouble Code DTC 26 8 Diagnostics Chart with Diagnostic Trouble 28 BASIC DIAGNOSTIC PROCEDURE CRUISE CONTROL SYSTEM DIAGNOSTICS 1 Basic Diagnostic Procedure A PROCEDURE Is cruise control main switch to step 2 Go to symptom 1 START DIAGNOSIS 1 Perform pre inspection Ref to CC 4 INSPECTION General Description 2 Check cruise control main switch operation turned ON Ref to CC 11 SYMPTOM CHART Diagnos tics Chart with Symptom PERFORM CRUISE CANCEL CONDITIONS 15 trouble
283. tch is turned OFF e ON and OFF 0 and battery voltage operation is alternately repeated while cruise control is operating e 0 volt is present when vehicle is stopped e Battery voltage is present during pressing the cruise control main switch and then battery voltage is present while main switch is turned ON e 0 volt is present when main switch is turned OFF CC 6 CRUISE CONTROL MODULE I O SIGNAL CRUISE CONTROL SYSTEM DIAGNOSTICS Measuring conditions and I O signals ignition switch ON and engine idling Brake switch Leave clutch pedal released MT while cruise contro main switch is turned ON Then check that e Battery voltage is present when brake pedal is released e O volt is present when clutch pedal is depressed Data link connector Data link connector m e 0 volt is present when brake pedal is depressed Vehicle speed sensor MT 19 Lift up the vehicle until all four wheels are raised off ground and then rotate any wheel manually Approx 5 and O volt pulse signals are alternately input to cruise control mod ule Additionally only in MT vehicle keep the cruise control main switch to ON and TCM AT Turn ignition switch to OFF NOTE leave brake pedal released Then check that Voltage at terminals 5 7 13 and 14 cannot be checked unless vehicle is driving by cruise control operation e Battery voltage is present when clutch ped
284. the Module gt SUPPLY Diagnos cruise control system tics Chart with 3 Check the operation current to the cruise Symptom gt control actuator motor CC 39 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS CC 40 OPTION PARTS OP Page Refer to G1831BE SUPPLEMENT for this section OPTION PARTS a SS General DESC ION 2 Rear Spoiler Crossbar Trailer Hitch Rear Dilferent al Protector ei ta p e hu a Resp amp 8432H933894 9 9249 58346508 8N NERHEUHEHS ws5sR Z52ABGSyV95228 4 RH4926 9853065905353 9 228Ba anAuNu u8 346G6923 8ARHZ4H8H 9 P uRHt499043955hAAoztnuumnposva Utest amp B EUV RZH4 52H2H5 56092390254999252 R9V 9458A2099888 25528H4BHRNBuUvu BC 69908254 895P uz 960b 99484042409285 BZ42 5 560 8U5 9028hNa4 uz497z7 eo0542 amp GENERAL DESCRIPTION OPTION PARTS _ 1 General Description A COMPONENT 1 REAR SPOILER 1 Rear spoiler 3 Retention cable Tightening torque N m kgf m ft lb 2 High mount stop lamp T 7 4 0 75 5 46 2 CROSSBAR 1 Front crossbar 2 Caution label Front
285. the hinges 2 TORSION BAR 1 Open the trunk lid 2 Using special tool remove the torsion bar from the hinge link ST 927780000 CAUTION During removal and installation carefully han dle torsion bar It will generate reactive force REMOVER 3 Remove the right left torsion bars CAUTION After the torsion bar is removed the trunk lid will slam shut Be careful not to get hit by the trunk lid B INSTALLATION 1 TRUNK LID 1 Install in the reverse order of removal 2 Install the trunk lid with uniform clearance Tightening torque 14 N m 1 8 kgf m 13 ft Ib 2 TORSION BAR 1 Install in the reverse order of removal 2 Apply the grease to rotating area of hinges and mating surface of torsion bar EB 18 REAR GATE PANEL 9 Rear Gate Panel A REMOVAL 1 REAR GATE PANEL 1 Disconnect the battery ground cable 2 Open the rear gate 3 Remove the rear gate outer handle lt Ref to SL 36 REMOVAL Rear Gate Outer Handle gt 4 Remove the rear gate latch assembly lt Ref to 51 37 REMOVAL Rear Gate Latch Assembly gt 5 Remove the rear gate key lock cylinders Ref to SL 44 REAR GATE REPLACEMENT Key Lock Cylinders gt 6 Remove the rear wiper lt Ref to WW 17 RE MOVAL Rear Wiper Motor gt 7 Disconnect the connectors of rear wiper rear de fogger and other lighting devices 8 Disconnect the washer hose 9 Remove the rubber duct A connection and pull Qut
286. the secu rity control module Front RH No 1 No 3 Rear LH No 1 No 3 Rear RH No 1 No 3 Rear gate No 1 No 2 Trunk lid No 1 No 2 and door switch 7 CHECK SECURITY INDICATOR LIGHT CIRCUIT CHECK SECURITY INDICATOR LIGHT 1 Disconnect the security control module har ness connector 2 Ground the harness connector terminal with a suitable wire Connector amp terminal B93 No 9 chassis ground CHECK POWER SUPPLY FOR SECURITY INDICATOR LIGHT 1 Disconnect the connector from the combina tion meter 2 Measure the voltage between the combina tion meter harness connector terminal and chassis ground Connector amp terminal 110 No 10 chassis ground CHECK SECURITY INDICATOR LIGHT CIR CUIT Measure the resistance between the combina tion meter harness connector terminal and security control module harness connector ter minal Connector amp terminal i11 No 6 B93 No 9 Does the security indicator light illuminate Replace the secu rity control mod ule Is the voltage more than 10 V Go to step 3 Is the resistance less than 10 Replace the com bination meter printed circuit SL 25 Go to step 2 Check the harness for open circuits and shorts between the com bination meter and the fuse Check the harness for open circuits and shorts between the com bination meter and security control module SECURITY SYSTEM SECURITY
287. tion Q Go to step 5 speed sensor switch and vehicle 2 Turn ignition switch to ON speed sensor 3 Measure voltage between vehicle speed sensor harness connector terminal and chas Replace cruise control module lt Ref to CC 5 Cruise Control sis ground Module gt Repair harness Is the resistance less than 10 2 Repair harness Replace vehicle speed sensor CC 31 DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE CRUISE CONTROL SYSTEM DIAGNOSTICS Check Yes Is the resistance less than 10 Go to step 7 CHECK HARNESS BETWEEN CRUISE CON TROL MODULE AND TRANSMISSION CON TROL MODULE 1 Disconnect harness connector from trans mission control module and cruise control module 2 Measure resistance between cruise control module harness connector terminal and trans mission control module harness connector ter minal CAUTION To measure the voltage and or resistance use 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 Connector amp terminal Turbo model B94 No 19 B56 No 17 Non turbo model B94 No 19 B55 No 13 CHECK TRANSMISSION CONTROL MOD ULE 1 Connect harness connector to transmission control module 2 Set the vehicle on free roller or lift up the vehicle and support with safety stands Warning Be careful not to be caught by the running wheels
288. tion lt Ref to AC 21 OPERATION Compressor Oil gt i 2 Stop the engine 3 Close the valves on the low high pressure sides of the manifold gauge set Low pressure gauge Compound pressure gauge High pressure gauge 4 Install the low high pressure hoses to the ser vice ports on the low high pressure sides of the vehicle respectively Low pressure gauge Compound pressure gauge High pressure gauge service 1 port oa G4M0586 5 Connect the center hose to the refrigerant recov ery system 6 Follow the operation manual to activate the re frigerant recovery system AC 16 REFRIGERANT CHARGING PROCEDURE 4 Refrigerant Charging Proce dure A OPERATION CAUTION e During operation be sure to wear safety gog gles and protective gloves Before charging the refrigerant evacuate the system to remove small amounts of moisture remaining in the system The moisture in the system can be completely evacuated only under the minimum vacuum level The minimum vacuum level affects the temperature in the system e The list below shows the vacuum values nec essary to boil water in various temperature In addition the vacuum levels indicated on the gauge are approx 3 3 kPa 25 mmHg 0 98 inHg lower than those measured at 304 8 m 1 000 ft above sea level am CC fala ve Vacuum level required to boil water at sea level Temperature 1 7 C 35 F 7 2 45 F 12 8 C 55 F
289. to remove the cross bar 1 TORX bolt T30 2 End support 3 Roof rail 4 Lower clamp CAUTION Pay attention to avoid damage to the roof panel during removal or installation B INSTALLATION 1 Rotate the lower clamp of each end support about 90 degrees downward 2 Set the front crossbar so that front direction mark on the right side top face of crossbar point in the di rection of vehicle front 3 Place the crossbar end support at position 76 2 mm 3 in behind the joint of front roof rail support and roof rail Length A 76 2 mm 3 in 1 Front of vehicle 2 Front direction mark 3 Caution label Front crossbar 4 Set the rear crossbar so that front direction mark on the right side top face of crossbar point in the di rection of vehicle front 5 Place the crossbar end support on a joint of rear roof rail support and roof rail 1 Front of vehicle 2 Front direction mark 6 Tighten the end support and clamp using TORX bolt T30 OP 6 TRAILER HITCH OPTION PARTS 4 Trailer Hitch 5 Remove the trailer hitch while lowering tail pipe CAUTION Eo Because the trailer hitch is heavy two people are required to install it Install in the reverse order of removal Because the trailer hitch is heavy two people are required to remove it 1 Lift up the vehicle 2 Remove the rubber cushion from tail pipe Tightening torque Trailer hitch to body 95 N m 9 7 kgf m 70 ft Ib
290. ve the rear quarter trim lt Ref to El 47 WAGON REMOVAL Rear Quarter Trim 5 Disconnect the connector and then detach the rear combination light assembly 3 Remove the trunk side trim of rear portion 4 Remove four nuts and then detach the rear com bination light while disconnecting the connector e EL aS JY Ib BOO034 2 WAGON 1 Disconnect the ground terminal from battery 2 Remove the clips and then detach the rear com bination light covers B INSTALLATION Install in the reverse order of removal LI 18 STOP TAIL LIGHT BULB LIGHTING SYSTEM 17 Stop Tail Light Bulb A REMOVAL 1 SEDAN 1 Remove the trunk side trim of rear portion 2 Turn the socket and remove the bulb A Stop light B Tail light C Tail stop lignt 2 WAGON 1 Remove the rear combination light assembly lt Ref to LI 18 WAGON REMOVAL Rear Combi nation Light Assembly gt 2 Turn the socket and remove the bulb B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Visually check the bulb for blow out 2 Check the bulb specification Ref to 1 2 SPECIFICATIONS General Description gt 3 If NG replace the bulb with a new one LI 19 BACK UP LIGHT BULB LIGHTING SYSTEM 18 Back up Light Bulb A REMOVAL 1 SEDAN 1 Remove the trunk side trim of rear portion 2 Turn the socket and remove the bulb 2 WAGON 1 Remove the rear combination
291. warning light operates properly When inspecting the airbag main harness disconnect the airbag module connector of the driver and passenger seats for safety reasons WIRING DIAGRAM AIRBAG CONTROL MODULE INFLATOR PASSENGER SIDE REO053 AB 38 DIAGNOSTIC CHART WITH TROUBLE CODE AIRBAG SYSTEM DIAGNOSTICS Yes Replace the pas senger airbag module lt Ref to AB 13 Passen ger s Airbag Mod ule CHECK PASSENGER S AIRBAG MODULE Does the airbag warning light 1 Turn the ignition switch OFF disconnect the operate properly battery ground terminal and wait more than 20 seconds 2 Remove the glove box 3 Disconnect the connector AB10 from AB9 4 Connect the connector 1F in the test har ness F to connector AB9 5 Connect the airbag resistor to connector in the test harness F 6 Connect the battery ground terminal and turn the ignition switch ON CHECK AIRBAG MAIN HARNESS Is the resistance less than 10 1 Turn the ignition switch OFF disconnect the battery ground terminal and wait more than 20 seconds 2 Disconnect the airbag resistor from the con nector in test harness F 3 Remove lower cover and disconnect the con nector AB3 from AB8 4 Disconnect the connector AB6 from the bag control module and connect the connector 11 in the test harness or I2 Ref to AB 15 Airbag Control Module gt 5 Measure the resistance between connector 21
292. with alcohol Do not use thinner since the coated area tends to melt Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 min utes Recommended surfacer e UPS 300 Flex Primer e No 303 UPS 300 Exclusive hardener Leave unattended Primer surfacer coating NPS 725 Exclusive Reducer thinner e Mixing ratio 2 1 UPS 300 No 303 e Viscosity 12 14 sec 20 C 68 F e Coated film thickness 40 50u Allow the coated surface to dry for 60 minutes at 20 C 68 F or 30 minutes at 60 C 140 F Sanding Ill Sand the coated surface and its surrounding areas using 400 sand paper and water Cleaning Same as Process No 12 degreasing El 28 FRONT BUMPER Pro cess Process name Job contents No Solid color Metallic color Use a block coating method Use a block coating method Recommended paint e Recommended paint Suncryl SC Suncryl SC No 307 Flex Hardener No 307 Flex Hardener SC Reducer thinner SC Reducer thinner e Mixing ratio 3 1 e Mixing ratio 3 1 Suncryl SC vs No 307 Flex Hardener Suncryl SC vs No 307 Flex Hardener e Viscosity 11 13 sec 20 C 68 F e Viscosity 11 13 sec 20 C 68 F e Coated film thickness 40 50u Coated film thickness 20 30u e Spraying thickness 245 343 kPa e Spraying thickness 245 343 kPa 2 5 3 5 kg cm 36 50 psi 2 5 3
293. y additional transmitter can also be programmed at this time Repeat steps 6 through 9 for an addi tional transmitter 10 Remove the ignition key from the ignition switch 11 The horn will chirp three times to indicate that the system has exited the programming mode 12 Check the keyless entry system properly oper ates by operating each transmitter SL 51 KEYLESS TRANSMITTER SECURITY AND LOCKS SL 52 EXTERIOR INTERIOR TRIM 1 General Description E Cie ed NETTES 3 H600 GNE DET 4 Front Under Cover 5 gt Front BUMD oon avid aa ended o BearBumbDOHPuss setae naai Zo Mud Guard c tecto EE ipte ei eia Und MEE I II 95 PIODL SDOIIGE beet ev epo east Hd uds S RR UR 10 Rear Spole is co acean Cet TVs Side SIE SDOIBE iom rie 12 Front Door TAM ausa ehe HESSE ERE SCR MN IA FRE 1 BearDoot TAM usos oA HE REA ea Io ERE SYN I US 14 Glove BOX uie gestire tio diee utes to dvi dtu OI Deed 15 doof Ball tvi toi diua Ras 16 Console BOX einen ise Poetics m mA 17 Instrument Panel Assembly 18 Upperlnner TUI ioni o Ioas 19 Lower Inner Trim MP T 20 Rear Quarter 21 SUN VISOR 22 ROOTA een tad E nio a tot mb RUINIS 23 Rear Gate

6 - Body - Ken Gilbert

Contents

Download Pdf Manuals

Related Search

Related Contents