TF-4
PRECAUTIONS
Revision: 2005 July 2005 FX
Service Notice or PrecautionsADS000RJ
Do not reuse transfer fluid, once it has been drained.
Check the fluid level or replace the fluid only with the vehicle parked on level ground.
During removal or installation, keep inside of transfer clear of dust or dirt.
Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern.
Fitting improper size and unusual wear tires applies excessive force to vehicle mechanism and can cause
longitudinal vibration.
Disassembly should be done in a clean work area, it is preferable to work in dustproof area.
Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
parts from becoming contaminated by dirt or other foreign matter.
All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
Check for the correct installation status prior to removal or disassembly. If matching marks are required,
be certain they do not interfere with the function of the parts when applied.
Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.
Gaskets, seals and O-rings should be replaced any time when the transfer is disassembled.
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
Observe the specified torque when assembling.
Clean and flush the parts sufficiently and blow-dry them.
Be careful not to damage sliding surfaces and mating surfaces.
Clean innerparts with lint-free cloth or towels. Do not use cotton work gloves and rags to prevent adhering
fibers.
TF-10
AWD SYSTEM
Revision: 2005 July 2005 FX
AWD SYSTEMPFP:41650
Power Transfer DiagramADS000RV
System DescriptionADS000RW
DESCRIPTION
Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
Makes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.
On roads which do not require AWD, it contributes to improved fuel economy by driving in conditions close
to rear-wheel drive.
Sensor inputs determine the vehicle's turning condition, and in response tight cornering/braking are con-
trolled by distributing optimum torque to front wheels.
NOTE:
When driving, if there is a large difference between front and rear wheel speed which continues for a long
time, fluid temperature of drive system parts becomes too high and AWD warning lamp flashes rapidly.
(When AWD warning lamp flashes, vehicle changes to rear-wheel drive conditions.) Also, optional distri-
bution of torque sometimes becomes rigid before lamp flashes rapidly, but it is not malfunction.
If AWD warning lamp is flashing rapidly, stop vehicle and allow it to idle for some time. Flashing will stop
and AWD system will be restored.
When driving, AWD warning lamp may flash slowly if there is a significant difference in diameter of the
tires. At this time, vehicle performance is not fully available and cautious driving is required. (Continues
until engine is turned OFF.)
If the warning lamp flashes slowly during driving but remains OFF after engine is restarted, the system is
normal. If it again flashes slowly after driving for some time, vehicle must be inspected.
When the difference of revolution speed between the front and rear wheel mode the shift occasionally
changes to direct 4-wheel driving conditions automatically. This is not malfunction.
SDIA1611E
TF-12
AWD SYSTEM
Revision: 2005 July 2005 FX
AWD WARNING LAMP
Turns ON when there is a malfunction in AWD system. It indicates that fail-safe mode is engaged and vehicle
change to rear-wheel drive or shifting driving force-AWD (Front-wheels still have some driving torque).
Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1
seconds after the engine starts if system is normal.
AWD Warning Lamp Indication
System DiagramADS000RX
Condition AWD warning lamp
Lamp check Turns ON when ignition switch is turned ON. Turns OFF
approx. 1 second after engine start.
AWD system malfunction ON
Protection function is activated due to heavy load to electric con-
trolled coupling. (AWD system is not malfunctioning and AWD system
changes to 2WD mode.) Rapid flashing: 2 times/second
(Flashing in approx. 1 minute and then turning OFF.)
Large difference in diameter of front/rear tires Slow flashing: 1 time/2 seconds
(Continuing to flash until turning ignition switch OFF)
Other than above (system normal) OFF
SDIA2160E
TROUBLE DIAGNOSIS FOR SYMPTOMS TF-37
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B
TF
Revision: 2005 July 2005 FX
3. SYMPTOM CHECK
Check again.
OK or NG
OK >> INSPECTION END
NG >> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of
clutch is not possible.). Refer to TF-45, "
Disassembly and Assembly" .
While Driving, AWD Warning Lamp Flashes Rapidly (When Flashing in Approx.
1 Minute and Then Turning OFF)
ADS000U1
NOTE:
Rapid flashing: 2 times/second
This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and
multiple disc clutch temperature increases. Also, optional distribution of torque sometimes becomes rigid
before lamp flashes rapidly. Both cases are not malfunction.
When this symptom occurs, stop vehicle and allow it to idle for some times. Flashing will stop and system will
be restored.
While Driving, AWD Warning Lamp Flashes Slowly (When Continuing to Flash
until Turning Ignition Switch OFF)
ADS000U2
NOTE:
Slow flashing: 1 time/2 seconds
DIAGNOSTIC PROCEDURE
1. CHECK TIRE
Check the following.
Tire pressure
Wear condition
Longitudinal tire size (There is no difference between longitudinal tires.)
OK or NG
OK >> GO TO 2.
NG >> Drive at vehicle speed of 20 km/h (12 MPH) or more for 5 seconds or more after repairing or
replacing damaged parts. (Initialize improper size tire information.)
2. CHECK INPUT SIGNAL OF TIRE DIAMETER
With CONSULT-II
1. Start engine.
2. Drive at 20 km/h (12 MPH) or more for approx. 200 seconds.
3. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-II.
4. Check monitor “DIS-TIRE MONI”.
Display of
“DIS-TIRE MONI”
“0-4mm”>> INSPECTION END
Except for “0-4mm”>>GO TO 3.
SDIA1900E
WT-1
ROAD WHEELS & TIRES
E SUSPENSION
CONTENTS
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SECTION WT
A
B
WT
Revision: 2005 July 2005 FX
ROAD WHEELS & TIRES
PREPARATION ........................................................... 2
Special Service Tools .......................................... ..... 2
Commercial Service Tools ................................... ..... 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... ..... 3
NVH Troubleshooting Chart ................................ ..... 3
ROAD WHEEL ....................................................... ..... 4
Inspection ............................................................ ..... 4
ALUMINUM WHEEL ........................................ ..... 4
STEEL WHEEL ................................................ ..... 4
ROAD WHEEL TIRE ASSEMBLY ......................... ..... 5
Balancing Wheels (Bonding Weight Type) .......... ..... 5
REMOVAL ........................................................ ..... 5
WHEEL BALANCE ADJUSTMENT ................. ..... 5
Tire Rotation ........................................................ ..... 6
LOW TIRE PRESSURE WARNING SYSTEM ....... ..... 7
System Components ........................................... ..... 7
System Description ............................................. ..... 7
TRANSMITTER ................................................ ..... 7
REMOTE KEYLESS ENTRY RECEIVER ........ ..... 7
BCM (BODY CONTROL MODULE) ................. ..... 8
LOW TIRE PRESSURE WARNING LAMP ...... ..... 8
DISPLAY UNIT ................................................. ..... 8
CAN COMMUNICATION ....................................... ..... 9
System Description ............................................. ..... 9
TROUBLE DIAGNOSES ....................................... ... 10
Schematic ........................................................... ... 10
Wiring Diagram ................................................... .... 11
Control Unit Input/Output Signal Standard .......... ... 14
ID Registration Procedure ................................... ... 16
ID REGISTRATION WITH ACTIVATION TOOL ... 16
ID REGISTRATION WITHOUT ACTIVATION
TOOL ............................................................... ... 17
Transmitter Wake Up Operation .......................... ... 18
WITH ACTIVATION TOOL ............................... ... 18
Self-Diagnosis ..................................................... ... 19
DESCRIPTION ................................................. ... 19
FUNCTION ....................................................... ... 19
LOW TIRE PRESSURE WARNING LAMP DIAG-
NOSTIC CHART .............................................. ... 19 CONSULT-II ......................................................
... 20
WORK SUPPORT MODE ................................ ... 21
SELF-DIAGNOSTIC RESULTS MODE ............ ... 21
DATA MONITOR MODE ................................... ... 22
ACTIVE TEST MODE ...................................... ... 22
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ................................................... ... 25
INTRODUCTION .............................................. ... 25
WORK FLOW ................................................... ... 25
Preliminary Check ............................................... ... 26
Malfunction Code/Symptom Chart ....................... ... 27
TROUBLE DIAGNOSIS FOR SELF-DIAGNOSTIC
ITEMS ..................................................................... ... 28
Inspection 1: Transmitter or Control Unit (BCM) .. ... 28
MALFUNCTION CODE NO. 21, 22, 23 OR 24 ... 28
Inspection 2: Transmitter - 1 ................................ ... 28
MALFUNCTION CODE NO. 31, 32, 33, 34, 41,
42, 43, 44, 45, 46, 47 OR 48 ............................ ... 28
Inspection 3: Transmitter - 2 ................................ ... 29
MALFUNCTION CODE NO. 35, 36, 37 OR 38 ... 29
Inspection 4: Vehicle Speed Signal ..................... ... 30
MALFUNCTION CODE NO. 52 ........................ ... 30
TROUBLE DIAGNOSIS FOR SYMPTOMS ........... ... 31
Inspection 1: Warning Lamp Does Not Come On
When Ignition Switch Is Turned On ..................... ... 31
Inspection 2: Warning Lamp Stays On When Ignition
Switch Is Turned On ............................................ ... 31
Inspection 3: Warning Lamp Blinks When Ignition
Switch Is Turned On ............................................ ... 33
Inspection 4: Turn Signal Lamp Blinks When Ignition
Switch Is Turned On ............................................ ... 34
Inspection 5: ID Registration Can Not Be Completed ... 34
REMOVAL AND INSTALLATION .......................... ... 35
Transmitter .......................................................... ... 35
REMOVAL ........................................................ ... 35
INSTALLATION ................................................ ... 35
SERVICE DATA ..................................................... ... 37
Road Wheel ......................................................... ... 37
Tire ...................................................................... ... 37
Tightening Torque ................................................ ... 37
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING WT-3
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WT
Revision: 2005 July 2005 FX
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartAES000JK
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: Applicable
Reference page
FAX-4
,
FSU-6 WT-4—
—
—
—
—
—
NVH in PR section
NVH in RFD section
NVH in FAX and FSU section
NVH in RAX and RSU section
Refer to TIRES in this chart.
Refer to ROAD WHEEL in this chart.
NVH in FAX, RAX section
NVH in BR section
NVH in PS section
Possible cause and SUSPECTED PARTS
Improper installation, looseness
Out-of-round
Imbalance
Incorrect tire pressure
Uneven tire wear
Deformation or damage
Non-uniformity
Incorrect tire size
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE AND FRONT SUSPENSION
REAR AXLE AND REAR SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKE
STEERING
Symptom TIRES Noise
× ×××××× ×××× ××××
Shake × ××××× ×× ×× ××××
Vibration ×××××××
Shimmy × ××××××× ×× × ××
Judder × ××××× × ×× × ××
Poor quality ride
or handling × ××××× × ×× ×
ROAD WHEEL Noise
× ×× × ××××× ×××
Shake × ×× × × ××× ×××
Shimmy, Judder × ×× × ××× ××
Poor quality ride
or handling × ×× × ×××
WT-4
ROAD WHEEL
Revision: 2005 July 2005 FX
ROAD WHEELPFP:40300
InspectionAES000OP
ALUMINUM WHEEL
1. Check tires for wear and improper inflation.
2. Check wheels for deformation, cracks and other damage. If deformed, remove wheel and check wheel runout.
a. Remove tire from aluminum wheel and mount on a tire balance machine.
b. Set dial indicator as shown in the figure.
STEEL WHEEL
1. Check tires for wear and improper inflation.
2. Check wheels for deformation, cracks and other damage. If deformed, remove wheel and check wheel runout.
a. Remove tire from steel wheel and mount wheel on a tire balance machine.
b. Set two dial indicators as shown in the figure.
c. Set each dial indicator to 0.
d. Rotate wheel and check dial indicators at several points around the circumference of the wheel.
e. Calculate runout at each point as shown below.
f. Select maximum positive runout value and the maximum nega- tive value.
Add the two values to determine total runout.
In case a positive or negative value is not available, use the
maximum value (negative or positive) for total runout.
If the total runout value exceeds the limit, replace steel wheel. Wheel runout (Dial indicator value):
Refer to WT-37, "
SERVICE DATA"
SFA975B
Radial runout = (A + B)/2
Lateral runout = (C + D)/2
Wheel runout : Refer to WT-37, "
SERVICE DATA"SFA981B
WT-6
ROAD WHEEL TIRE ASSEMBLY
Revision: 2005 July 2005 FX
c. If calculated balance weight value exceeds 50 g (1.76 oz), install
two balance weight sheets in line with each other (as shown in
the figure).
CAUTION:
Do not install one balance weight sheet on top of another.
3. Start wheel balancer again.
4. Install drive-in balance weight on inner side of road wheel in the wheel balancer indication position (angle).
CAUTION:
Do not install more than two balance weights.
5. Start wheel balancer. Make sure that inner and outer residual unbalance values are 5.0 g (0.2 oz) each or below.
If either residual unbalance value exceeds 5.0 g (0.2 oz), repeat installation procedures.
Wheel balance (Maximum allowable unbalance):
Tire RotationAES000ON
After rotating the tires, adjust the tire pressure.
Retighten the wheel nuts when the vehicle has been driven for
1,000 km (600 miles) (also in cases of a flat tire, etc.).
CAUTION:
Do not include the T-type spare tire when rotating the tires.
When installing wheels, tighten them diagonally by dividing
the work two to three times in order to prevent the wheels
from developing any distortion.
Maximum allowable
unbalance Dynamic (At rim flange) 5.0 g (0.2 oz) (one side)
Static (At rim flange) 20 g (0.7 oz)
SMA056D
Tightening torque of wheel nut : 112.5 N·m (11 kg, 83 ft-lb)
SMA829C