PG-20
IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
All Items, Main Items, Selection From Menu
NOTE:
Perform monitoring of IPDM E/R data with the ignition switch ON. When the ignition switch is at ACC, the display may not be cor-
rect.
*1: The vehicle without the Intelligent Key system displays only ON without change.
*2: This item is displayed, but does not function.
ACTIVE TEST
Operation Procedure
1. Touch “ACTIVE TEST” on “SELECT DIAG MODE” screen.
2. Touch item to be tested.
3. Touch “START”, and confirm its operation.
4. Touch “OFF” while testing to stop the operation.
CONSULT-II
screen displayItem name Display or unitMonitor item selection
Description
ALL
SIGNALSMAIN
SIGNALSSELEC-
TION
FROM
MENU
MOTOR FAN REQ Motor fan request 1/2/3/4×× ×Signal status input from ECM
AC COMP REQ Compressor request ON/OFF×× ×Signal status input from ECM
TAIL&CLR REQ Tail & clear request ON/OFF×× ×Signal status input from BCM
HL LO REQ Headlamp LO request ON/OFF×× ×Signal status input from BCM
HL HI REQ Headlamp HI request ON/OFF×× ×Signal status input from BCM
FR FOG REQ Front fog request ON/OFF×× ×Signal status input from BCM
HL WASHER REQHeadlamp washer
requestON/OFF××Signal status input from head-
lamp washer switch
FR WIP REQ Front wiper requestSTOP/1LOW/
LOW/HI×× ×Signal status input from BCM
WIP AUTO STOP Wiper auto stop ACT P/STOP P×× ×Output status of IPDM E/R
WIP PROT Wiper protection OFF/BLOCK×× ×Control status of IPDM E/R
ST RLY REQ
*1Starter request ON/OFF××Status of input signal
IGN RLY Ignition relay status ON/OFF×× ×Ignition relay status monitored
with IPDM E/R
RR DEF REQRear window defogger
requestON/OFF×× ×Signal status input from BCM
OIL P SW Oil pressure switch OPEN/CLOSE××Signal status input in IPDM E/R
DTRL REQ*
2Daytime running light
requestON/OFF××—
HOOD SW
*2Hood switch ON/OFF××—
THFT HRN REQTheft warning horn
requestON/OFF××Signal status input from BCM
HORN CHIRP
*2Horn chirp ON/OFF××—
CONSULT-II screen display Test item Description
TAIL LAMPParking, license plate and tail
lamps operationTail lamp relay is operated by switching operation ON-OFF.
REAR DEFOGGER Rear window defogger operation Rear defogger relay is operated by switching operation ON-OFF.
IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
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NOTE:
High beam headlamp repeats high beam and low beam every 1 second. When high beam headlamp of xenon type operates, the head-
lamp perform the HIGH-LOW changeover operation without illuminating the headlamp bulb.
Auto Active TestBKS002EW
DESCRIPTION
In auto active test mode, operation inspection can be performed when IPDM E/R sends a drive signal to
the following systems:
–Rear window defogger
–Front wiper
–Parking, license plate and tail lamps
–Front fog lamp
–Headlamp (HI, LO)
–A/C compressor (magnet clutch)
–Cooling fan
–Oil pressure warning lamp
OPERATION PROCEDURE
1. Close hood and front door (passenger side), and then lift wiper arms away from windshield (to prevent
glass damage by wiper operation).
NOTE:
When auto active test is performed with hood opened, sprinkle water on windshield beforehand.
2. Turn ignition switch OFF.
3. Turn ignition switch ON, and within 20 seconds, press driver's door switch 10 times (close the other
doors). Then turn ignition switch OFF.
4. Turn ignition switch ON within 10 seconds after ignition switch OFF.
5. When auto active test mode is actuated, horn chirps once. Oil pressure warning lamp starts blinking.
6. After a series of operations is repeated three times, auto active test is completed.
NOTE:
When auto active test mode has to be cancelled halfway, turn ignition switch OFF.
CAUTION:
Be sure to inspect door switch when the auto active test cannot be performed.
FRONT WIPER Front wiper (HI, LO) operationFront wiper relay and front wiper high relay are operated by switch-
ing operation (OFF: OFF, HI: high speed, LO: low speed).
MOTOR FAN Cooling fan operationCooling fan relay-1, 2 and 3 are operated by switching operation
(1: OFF, 2: LO, 3: MID, 4: HI).
HEAD LAMP WASHER Headlamp washer operation Headlamp washer relay is operated by switching operation ON-OFF.
LAMPSHigh beam headlamp and low
beam headlamp operation
NOTEHeadlamp low relay and headlamp high relay are operated by
switching operation (OFF: OFF, HI: high beam, LO: low beam).
Front fog lamp operationFront fog lamp relay is operated by switching operation
(OFF: OFF, FOG: ON).
HORN Horn operation Touch “ON” button, horn relay operates 20 ms.CONSULT-II screen display Test item Description
PG-22
IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
INSPECTION IN AUTO ACTIVE TEST MODE
When auto active test mode is actuated, the following eight steps are repeated three times.
NOTE:
A dotted line shows a position of HIGH beam of Halogen headlamp.
NOTE:
When high beam headlamp of xenon type operates, the headlamp perform the HIGH-LOW changeover operation without illuminating
the headlamp bulb.
SKIB8863E
Operation
orderTest item Operation time / frequency
1 Rear window defogger 10 seconds
2 Front wiper LO 5 seconds HI 5 seconds
3 Parking, license plate and tail lamps 10 seconds
4 Front fog lamp 10 seconds
5 Headlamp (LO) 10 seconds
6
Headlamp (HI)
NOTEON 2 seconds ⇔ OFF 2 seconds (5 times)
7 A/C compressor (magnet clutch) ON 2 seconds ⇔ OFF 2 seconds (5 times)
8 Cooling fanLO 2 seconds MID 2 seconds HI 2 seconds MID 2 seconds
LO 2 seconds
A Oil pressure warning lamp Oil pressure warning lamp is blinking when the auto active test operating.
IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
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Concept of Auto Active Test
IPDM E/R actuates auto active test mode when it receives door switch signal from BCM via CAN commu-
nication line. Therefore, when auto active test mode is activated successfully, CAN communication
between IPDM E/R and BCM is normal.
If any of systems controlled by IPDM E/R cannot be operated, possible cause can be easily diagnosed
using auto active test.
Diagnosis chart in auto active test mode
Symptom Inspection contents Possible cause
Any of front wiper, park-
ing, license plate and
tail lamps, front fog
lamp, and headlamp
(HI, LO) do not operate.Perform auto active
test. Does system in
question operate?YES
BCM signal input system malfunction
NO
Lamp/wiper motor malfunction
Lamp/wiper motor ground circuit malfunction
Harness/connector malfunction between IPDM E/R and system in ques-
tion
IPDM E/R (integrated relay) malfunction
Rear window defogger
does not operate.Perform auto active
test. Does rear win-
dow defogger oper-
ate?YES
BCM signal input circuit malfunction
NO
Rear window defogger relay malfunction
Harness/connector malfunction between IPDM E/R and rear window
defogger relay
Open circuit of rear window defogger
IPDM E/R malfunction
A/C compressor does
not operate.Perform auto active
test. Does magnetic
clutch operate?YES
BCM signal input circuit malfunction
CAN communication signal between BCM and ECM.
CAN communication signal between ECM and IPDM E/R
NO
Magnetic clutch malfunction
Harness/connector malfunction between IPDM E/R and magnetic clutch
IPDM E/R (integrated relay) malfunction
Cooling fan does not
operate.Perform auto active
test. Does cooling fan
operate?YES
ECM signal input circuit
CAN communication signal between ECM and IPDM E/R
NO
Cooling fan motor malfunction
Harness/connector malfunction between IPDM E/R and cooling fan
motor
IPDM E/R (integrated relay) malfunction
Oil pressure warning
lamp does not operate.Perform auto active
test. Does oil pres-
sure warning lamp
blink?YES
Harness/connector malfunction between IPDM E/R and oil pressure
switch
Oil pressure switch malfunction
IPDM E/R malfunction
NO
CAN communication signal between BCM and Unified Meter and A/C
Amp.
Combination meter
POWER STEERING FLUID
PS-7
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POWER STEERING FLUIDPFP:KLF20
Checking Fluid LevelBGS0003P
Check fluid level with the engine stopped.
Make sure that fluid level is between MIN and MAX.
Fluid levels at HOT and COLD are different. Do not confuse
them.
CAUTION:
The fluid level should not exceed the MAX line. Excessive
fluid will cause fluid leakage from the cap.
Do not reuse drained power steering fluid.
Checking Fluid LeakageBGS0003Q
Check hydraulic connections for fluid leakage, cracks, damage,
looseness, or wear.
1. Run engine until the fluid temperature reaches 50 to 80°C
(122 to 176°F) in reservoir tank, and keep engine speed idle.
2. Turn steering wheel several times from full left stop to full right
stop.
3. Hold steering wheel at each lock position for five seconds and
carefully, check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 10 seconds. (There is the possibility that oil pump may
be damaged.)
4. If fluid leakage at connections is noticed, then loosen flare nut and then retighten. Do not overtighten con-
nector as this can damage O-ring, washer and connector.
5. If fluid leakage from oil pump is noticed, check oil pump. Refer to PS-29, "
POWER STEERING OIL
PUMP" .
6. Check steering gear boots for accumulation of fluid, indicating from steering gear.
Air Bleeding Hydraulic SystemBGS0003R
If air bleeding is not complete, the following symptoms can be observed.
Bubbles are created in reservoir tank.
Clicking noise can be heard from oil pump.
Excessive buzzing in oil pump.
NOTE:
Fluid noise may occur in the steering gear or oil pump. This does not affect performance or durability of
the system.
1. Turn steering wheel several times from full left stop to full right stop with engine off.
CAUTION:
Filling reservoir tank with fluid so as not to lower fluid level below the MIN line while steering
wheel turning.
2. Start engine and hold steering wheel at each lock position for 3 seconds at idle to check for fluid leakage.
3. Repeat step 2 above several times at approximately 3 second intervals.
CAUTION:
Do not hold the steering wheel in a locked position for more than 10 seconds. (There is the possi-
bility that oil pump may be damaged.)
4. Check fluid for bubbles and white contamination.
5. Stop engine if bubbles and white contamination do not drain out. Perform steps 2 to 3 above after waiting
until bubbles and white contamination drain out.HOT : Fluid temperature 50 – 80°C (122 – 176°F)
COLD : Fluid temperature 0 – 30°C (32 – 86°F)
SGIA0232J
SGIA0506E
STEERING WHEEL
PS-9
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STEERING WHEELPFP:48430
On-Vehicle Inspection and ServiceBGS0003S
CHECKING CONDITION OF INSTALLATION
Check installation conditions of steering gear assembly, front suspension assembly, axle and steering col-
umn assembly.
Check if movement exists when steering wheel is moved up and down, to the left and right and to the axial
direction.
Check steering gear assembly mounting nut and bolts for looseness. Refer to PS-17, "COMPONENTS" .
CHECKING STEERING WHEEL PLAY
Turn steering wheel so that front wheels come to the straight-ahead position. Start engine and lightly turn
steering wheel to the left and right until front wheels start to move. Measure steering wheel movement on
the outer circumference.
When the measurement value is outside the standard value, check backlash for each joint of steering col-
umn assembly and installation condition of power steering gear assembly.
CHECKING NEUTRAL POSITION STEERING WHEEL
Make sure that steering gear assembly, steering column and steering wheel are installed in the correct
position.
Perform neutral position inspection after wheel alignment. Refer to FSU-5, "Wheel Alignment Inspection" .
Set vehicle to the straight-ahead position and confirm steering wheel is in the neutral position.
Loosen outer socket lock nut and turn inner socket to left and right equally to make fine adjustments if
steering wheel is not in the neutral position.
CHECKING STEERING WHEEL TURNING FORCE
1. Park vehicle on a level and dry surface, set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is
approximately 50 to 80°C (122 to 176°F).]
NOTE:
Tires need to be inflated normal pressure.
4. Check steering wheel turning force when steering wheel has
been turned 360° from neutral position.
NOTE:
Multiply the distance L from the hook of spring balance to the
center of steering wheel by the measurement value with a spring
balance.
5. If steering wheel turning force is out of the specification, check
rack sliding force and relief hydraulic pressure of oil pump.
Regarding relief hydraulic pressure of oil pump, refer to PS-29,
"CHECKING RELIEF OIL PRESSURE" .
a. Disconnect lower shaft and steering knuckle from steering gear assembly. Refer to FAX-5, "
COMPO-
NENT" , PS-12, "COMPONENTS" .
b. Start and run engine at idle to make sure steering fluid has reached normal operating temperature.Steering wheel axial end play : 0 mm (0 in)
Steering wheel play : 0 – 35 mm (0 – 1.38 in)
Steering wheel turning force
: Less than 45 N (4.6 kg, 10 lb)
SGIA1615E
POWER STEERING OIL PUMP
PS-29
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POWER STEERING OIL PUMPPFP:49110
On-Vehicle Inspection and ServiceBGS0003Y
CHECKING RELIEF OIL PRESSURE
CAUTION:
Make sure that belt tension is normal before starting the following procedure.
1. Connect the hydraulic pressure gauge [SST] between oil pump
discharge connector and high-pressure hose. Bleed air from the
hydraulic circuit while opening valve fully. Refer to PS-7, "
Air
Bleeding Hydraulic System" .
2. Start engine. Run engine until oil temperature reaches 50 to
80°C (122 to 176°F).
CAUTION:
Leave the valve of the hydraulic pressure gauge [SST]
fully open while starting and running engine. If engine is
started with the valve closed, the hydraulic pressure in
oil pump goes up to the relief pressure along with
unusual increase of oil temperature.
Be sure to keep hose clear of belts and other parts when engine is started.
3. Fully close the hydraulic pressure gauge [SST] valve with
engine at idle and measure the relief oil pressure.
CAUTION:
Never keep valve closed for 10 seconds or longer.
4. Open the valve slowly after measuring. Repair oil pump if the
relief oil pressure is outside the standard. Refer to PS-31, "
Dis-
assembly and Assembly (Except for QR20DE Models)" , PS-35,
"Disassembly and Assembly (QR20DE Models)" .
5. After inspection, disconnect the hydraulic pressure gauge [SST]
from hydraulic circuit, then add fluid and bleed air. Refer to PS-
7, "Air Bleeding Hydraulic System" .
Relief oil pressure
Except for QR20DE models8,000 - 8,800 kPa
(80 – 88 bar, 81.6 – 89.8 kg/cm
2 , 1,160 – 1,276 psi)
QR20DE models9,000 – 9,800 kPa
(90 – 98 bar, 91.8 – 100 kg/cm
2 , 1,305 – 1,421 psi)
SGIA0364E
SGIA0726E
RSU-2
PRECAUTIONS
PRECAUTIONSPFP:00001
CautionBES0003W
When installing rubber bushings, final tightening must be performed under unladen conditions with tires
on ground. Oil will shorten the life of rubber bushings. Be sure to wipe off any spilled oil.
–Unladen conditions mean that fuel, engine coolant and lubricant are full. A spare tire, a jack, hand tools
and mats are in designated positions.
After servicing suspension parts, be sure to check wheel alignment.
Self-locks nut are not reusable. Always use new ones when installing. Since new self-lock nut are pre-
oiled, tighten as they are.