ATC-142
REFRIGERANT LINES
Removal and Installation of CondenserBJS000HV
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove air duct (inlet). Refer to EM-17, "
AIR CLEANER AND AIR DUCT" (QR engine) or EM-131, "AIR
CLEANER AND AIR DUCT" (VQ engine).
3. Remove front grille. Refer to EI-20, "
FRONT GRILLE" .
4. Remove battery. Refer to SC-4, "
BATTERY" .
5. Remove mounting bolts, and then remove battery tray.
6. Remove mounting bolt from high-pressure flexible hose and
high-pressure pipe1.
7. Disconnect high-pressure flexible hose and high-pressure pipe
1 from condenser.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
8. Disconnect refrigerant pressure sensor connector.
9. Remove mounting bolts from condenser.
10. Remove condenser bracket.
11. Remove engine room harness clips from radiator core upper
support.
12. Remove engine room harness mounting resin nuts.
13. Remove radiator upper mount.
RJIA2301E
RJIA1853E
RJIA2233E
RJIA3326E
ATC-144
REFRIGERANT LINES
INSTALLATION
Install liquid tank, and then install liquid tank bracket on condenser.
CAUTION:
Make sure liquid tank bracket is securely installed at protru-
sion of condenser. (Make sure liquid tank bracket does not
move to a position below center of liquid tank.)
Replace O-rings of A/C piping with new ones, and then
apply compressor oil to it when installing it.
When recharging refrigerant, check for leaks.
Removal and Installation of Refrigerant Pressure SensorBJS000HX
REMOVAL
1. Remove condenser. Refer to ATC-142, "Removal and Installation of Condenser" .
2. Remove refrigerant pressure sensor from condenser.
CAUTION:
When working, be careful not to damage the condenser
fins.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
Apply compressor oil to O-ring of refrigerant pressure sensor when installing it.
Removal and Installation of EvaporatorBJS000HY
REMOVAL
1. Remove low-pressure pipe 2 and high-pressure pipe 2. Refer to ATC-140, "Removal and Installation of
Low-pressure Pipe 2 and High-pressure Pipe 2" .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
2. Slide evaporator, and then remove it from heater & cooling unit
assembly.
3. Remove intake sensor from evaporator, and then remove evap-
orator.
RJIA1861E
RJIA2237E
RJIA3281E
REFRIGERANT LINES
ATC-145
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INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
Replace O-rings of A/C piping with new ones, and then apply compressor oil to it when installing
it.
Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping
straight in axial direction.
Insert piping securely until a click is heard.
After piping connection is completed, pull male-side piping by hand to make sure that connection
does not come loose.
O-rings are different from low-pressure pipe 1 (high-pressure pipe 2) and low-pressure pipe 2
(high-pressure pipe 3).
Mark the mounting position of intake sensor bracket prior to removal so that the reinstalled sen-
sor can be located in the same position.
When recharging refrigerant, check for leaks.
Removal and Installation of Expansion ValveBJS000HZ
REMOVAL
1. Remove evaporator. Refer to ATC-144, "Removal and Installation of Evaporator" .
2. Remove mounting bolts, and then remove expansion valve.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
Replace O-rings of evaporator with new ones, and then apply compressor oil to it when installing
it.
O-rings are different from low-pressure pipe 1 (high-pressure pipe 1) and low-pressure pipe 2
(high-pressure pipe 2).
When recharging refrigerant, check for leaks.
RJIA3327E
ATC-146
REFRIGERANT LINES
Checking for Refrigerant LeaksBJS000JF
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electrical leak detector or fluorescent dye leak
detector (SST: J-42220).
If dye is observed, confirm the leak with an electrical leak detector. It is possible a prior leak was repaired and
not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electrical leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electrical leak detector probe slower and closer to the suspected leak area will improve the
chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorBJS000JG
1. Check A/C system for leaks using the UV lamp and safety goggles (SST: J-42220) in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open-
ing indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (SST: J-43872) to prevent future
misdiagnosis.
4. Perform a system performance check and verify the leak repair with an approved electrical leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionBJS000JH
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2 , 50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (SST: J-41459).
3. Connect the injector tool to the A/C low-pressure side service valve.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool (SST: J-41459) (refer to the manufacture's
operating instructions).
6. With the engine still running, disconnect the injector tool from the service valve.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
8. Attach a blue label as necessary.
ATC-148
REFRIGERANT LINES
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Stop the engine.
2. Connect a suitable A/C manifold gauge set (SST) to the A/C service valves.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm
2 , 50 psi) above 16°C
(61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of
refrigerant.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa
(3.45 bar, 3.52 kg/cm
2 , 50 psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet g) to the
low-pressure side [evaporator drain hose h to shaft seal l (QR engine) or m (VQ engine)]. Refer to AT C -
133, "Components" . Perform a leak check for the following areas carefully. Clean the component to be
checked and move the leak detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.
Condenser
Check the fitting of high-pressure flexible hose and pipe, refrigerant pressure sensor.
Liquid tank
Check the fitting of refrigerant connection.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start the engine.
8. Set the A/C control as follows;
a. A/C switch: ON
b. Mode door position: VENT (Ventilation)
c. Intake door position: Recirculation
d. Temperature setting: Max. cold
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
BCM (BODY CONTROL MODULE)
BCS-9
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BCS
MAJOR COMPONENTS AND CONTROL SYSTEM
System Input Output
Remote control entry system
Remote keyless entry receiver
Key switch
Front door switch (driver side)
Front door switch (passenger side)
Rear door switch RH
Rear door switch LH
Front door lock assembly
(driver side) (door lock actuator)
Front door lock assembly
(passenger side) (door lock actuator)
Rear door lock actuator RH
Rear door lock actuator LH
Trunk lid opener actuator
Turn signal lamp (RH, LH)
Combination meter
(turn signal indicator, warning chime)
Intelligent Key system
Intelligent Key unit
Front door switch (driver side)
Front door switch (passenger side)
Rear door switch RH
Rear door switch LH
Front door lock assembly
(driver side) (door lock actuator)
Front door lock assembly
(passenger side) (door lock actuator)
Rear door lock actuator RH
Rear door lock actuator LH
Trunk lid opener actuator
Turn signal lamp (RH, LH)
Combination meter
(turn signal indicator, warning chime)
Power door lock system
Power window main switch
(door lock and unlock switch)
Front door lock assembly (driver side)
(door unlock sensor)
Key switch
Front door switch (driver side)
Front door switch (passenger side)
Rear door switch RH
Rear door switch LH
Front door lock assembly
(driver side) (door lock actuator)
Front door lock assembly
(passenger side) (door lock actuator)
Rear door lock actuator RH
Rear door lock actuator LH
Trunk lid openerTrunk lid and fuel lid opener switch
(Trunk lid opener switch)Trunk lid lock assembly
(trunk lid opener actuator)
Power supply (IGN) to power window,
sunroofIgnition power supply Power window and sunroof system
Power supply (BAT) to power window,
sunroof and power seatBattery power supply Power window, sunroof system and power seat
Headlamp Combination switch
IPDM E/R
Combination meter
(HIGH beam indicator)
Exterior lamp battery saver control
Ignition switch
Combination switchIPDM E/R
Auto light system
Optical sensor
Combination switch
Ignition switch (ACC, ON)IPDM E/R
Parking, license plate and tail lamps Combination switch
IPDM E/R
Combination meter (Tail lamp indicator)
Front fog lamp Combination switch
IPDM E/R
Combination meter
(Front fog lamp indicator)
BL-2 Check Door Lock Actuator Output Signal ............... 39
Check Door Lock Actuator Circuit .......................... 40
(DRIVER SIDE AND REAR LH) .......................... 40
(PASSENGER SIDE AND REAR RH) ................. 41
Check Door Unlock Sensor .................................... 42
FUEL FILLER LID OPENER ..................................... 44
Component Part and Harness Connector Location ... 44
Wiring Diagram –F/LID– ......................................... 45
REMOTE KEYLESS ENTRY SYSTEM ..................... 46
Component Parts and Harness Connector Location ... 46
System Description ................................................. 46
INPUTS ............................................................... 46
OPERATED PROCEDURE ................................. 47
CAN Communication System Description .............. 48
CAN Communication Unit ....................................... 48
Schematic ............................................................... 49
Wiring Diagram — KEYLES— ................................ 50
FIG. 1 ................................................................... 50
FIG. 2 ................................................................... 51
FIG. 3 ................................................................... 52
Terminals and Reference Value for BCM ................ 53
Terminals and Reference Value for IPDM E/R ........ 54
CONSULT-II Function (BCM) .................................. 54
CONSULT-II START PROCEDURE .................... 54
CONSULT-II APPLICATION ITEMS .................... 54
Work Flow ............................................................... 56
Trouble Diagnosis Symptom Chart ......................... 56
Check Key Fob Battery and Function ..................... 57
Check ACC Switch ................................................. 58
Check Door Switch ................................................. 59
CHECK DOOR SWITCH (EXCEPT TRUNK
ROOM LAMP SWITCH) ...................................... 59
CHECK TRUNK ROOM LAMP SWITCH ............ 61
Check Key Switch ................................................... 63
Check Hazard Function .......................................... 64
Check Map Lamp and Ignition Keyhole Illumination
Function .................................................................. 64
ID Code Entry Procedure ....................................... 64
KEY FOB ID SET UP WITH CONSULT-II ........... 64
KEY FOB ID SET UP WITHOUT CONSULT-II .... 66
Key Fob Battery Replacement ................................ 67
INTELLIGENT KEY SYSTEM ................................... 68
Component Parts and Harness Connector Location ... 68
System Description ................................................. 70
DOOR LOCK/UNLOCK, TRUNK OPEN FUNC-
TION .................................................................... 70
REMOTE KEYLESS ENTRY FUNCTIONS ......... 71
ENGINE START FUNCTION ............................... 72
WARNING AND ALARM FUNCTION .................. 73
CHANGE SETTINGS FUNCTION ....................... 76
INTELLIGENT KEY REGISTRATION .................. 76
STEERING LOCK UNIT REGISTRATION .......... 77
CAN Communication System Description .............. 77
CAN Communication Unit ....................................... 77
Schematic ............................................................... 78
Wiring Diagram — I/KEY— .................................... 80
Terminals and Reference Value for Intelligent Key
Unit ......................................................................... 88
Terminals and Reference Value for Steering Lock Unit .......................................................................... 90
Terminals and Reference Value for BCM ................ 90
Diagnosis Procedure ............................................... 91
WORK FLOW ...................................................... 91
ENGINE START FUNCTION DIAGNOSTIC
PROCEDURE ...................................................... 92
CONSULT-II Functions (INTELLIGENT KEY) ......... 93
CONSULT-II Inspection Procedure ......................... 93
BASIC OPERATION ............................................ 93
CONSULT-II Application Items ................................ 93
SELF-DIAGNOSTIC RESULTS ........................... 93
DATA MONITOR .................................................. 93
WORK SUPPORT ............................................... 94
ACTIVE TEST ...................................................... 95
Trouble Diagnosis Symptom Chart ......................... 96
ALL FUNCTIONS OF THE INTELLIGENT KEY
ARE NOT OPERATING ....................................... 96
REMOTE KEYLESS ENTRY FUNCTION MAL-
FUNCTION .......................................................... 96
DOOR LOCK FUNCTION MALFUNCTION ......... 97
TRUNK OPEN FUNCTION MALFUNCTION ....... 97
HAZARD REMINDER FUNCTION MALFUNC-
TION .................................................................... 98
ENGINE START FUNCTION MALFUNCTION .... 98
WARNING CHIME FUNCTION MALFUNCTION ... 99
Check CAN Communication System ....................100
Check Intelligent Key Unit Power Supply and
Ground Circuit .......................................................100
Check Key Switch (Intelligent Key Unit Input) .......101
Check Key Switch (BCM Input) .............................102
Check Ignition knob Switch ...................................103
Check Door Switch ...............................................105
CHECK DOOR SWITCH (EXCEPT TRUNK
ROOM LAMP SWITCH) .....................................105
CHECK TRUNK ROOM LAMP SWITCH ...........107
Check Door Request Switch .................................109
Check Intelligent Key Warning Buzzer .................. 111
Check Outside Key Antenna .................................112
Check Inside Key Antenna ....................................114
Check Steering Lock Unit ......................................115
Check Headlamp Function ....................................117
Removal and Installation of Intelligent Key Unit ....117
REMOVAL ..........................................................117
INSTALLATION ..................................................117
Intelligent Key Battery Replacement .....................117
DISASSEMBLY AND ASSEMBLY OF INTELLI-
GENT KEY .........................................................117
INTELLIGENT KEY BATTERY INSPECTION ...118
DOOR ......................................................................119
Fitting Adjustment .................................................119
FRONT DOOR ...................................................119
REAR DOOR .....................................................119
STRIKER ADJUSTMENT ..................................120
Removal and Installation of Front Door ................120
REMOVAL ..........................................................120
INSTALLATION ..................................................120
Removal and Installation of Rear Door .................120
REMOVAL ..........................................................121
BL-18
RADIATOR CORE SUPPORT
RADIATOR CORE SUPPORTPFP:62500
Removal and InstallationBIS000VT
REMOVAL
1. Remove front bumper. Refer to EI-14, "FRONT BUMPER" .
2. Remove head lamp (LH/RH). Refer to LT- 3 6 , "
Removal and Installation" (Xenon type), LT- 6 2 , "Removal
and Installation" (Conventional type)
3. Remove air duct clips, and then remove air duct.
4. Remove crash zone sensor. Refer to SRS-44, "
CRASH ZONE SENSOR" .
5. Remove hood lock assembly, and then hood lock cable. Refer to BL-16, "
Removal and Installation of
Hood Lock Control" .
6. Remove ambient sensor. Refer to ATC-109, "
AMBIENT SENSOR" .
7. Remove hydraulic piping clips and tabs. Refer to PS-39, "
HYDRAULIC LINE" .
8. Remove radiator core support lower harness clips and mounting bolts, and then remove radiator core sup-
port lower. Remove mounting bolts with power tool.
9. Disconnect horn connectors and remove harness clips.
10. Remove each harness clip and nuts of radiator core support. Remove nuts with power tool.
11. Remove condenser mounting bracket bolts.
1. Radiator core support side (RH) 2. Air guide (RH) 3. Bolt
4. Nut 5. Radiator core support lower 6. Nut
7. Radiator core support center 8. Bolt 9. Horn (High)
10. Horn (Low) 11. Clip 12. Air guide (LH)
13. Radiator core support side (LH) 14. Radiator core support upper 15. Nut
16. Bolt 17. Bolt
PIIB0266E