BR-24
< SERVICE INFORMATION >
REAR DISC BRAKE
REAR DISC BRAKE
On-vehicle InspectionINFOID:0000000003532743
PAD WEAR INSPECTION
• Inspect the thickness of pad through cylinder body inspection hole.
Use a scale for inspection if necessary.
Exploded ViewINFOID:0000000003532744
Standard thickness : 12.13 mm (0.478 in)
Repair limit thickness : 1.0 mm (0.039 in)
BRA0010D
1. Union bolt 2. Brake hose 3. Copper washer
4. Cap 5. Bleed valve 6. Bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Knuckle slide 12. Sliding sleeve boot
13. Sliding sleeve 14. Inner pad 15. Outer pad
(B) : Brake fluid (R) : Rubber grease (M) : Molykote M-77
⇐: Front
WFIA0453E
BR-26
< SERVICE INFORMATION >
REAR DISC BRAKE
2. Install cylinder body and tighten bolts to specification. Refer to BR-24, "Exploded View" .
CAUTION:
Before installing cylinder body to the vehicle, wipe off mating surface of cylinder body.
3. Install brake hose to cylinder body and tighten union bolt to specification as necessary. Refer to BR-24,
"Exploded View".
CAUTION:
• Do not reuse copper washers.
• Securely attach brake hose to protrusion on cylinder body.
4. Refill new brake fluid and bleed air as necessary. Refer to BR-8, "
Bleeding Brake System" .
5. Install tires to the vehicle. Refer to WT-7, "
Rotation" .
Brake CaliperINFOID:0000000003532747
DISASSEMBLY
1. Remove pads from cylinder body.
2. Remove sliding sleeve and boot from cylinder body.
3. Place a wooden block as shown, and blow air into union bolt
hole to remove piston and piston boot.
CAUTION:
Do not get your fingers caught in piston.
4. Using a suitable tool, remove piston seal from cylinder body as
shown.
CAUTION:
Be careful not to damage cylinder body inner wall.
CALIPER INSPECTION
Cylinder Body
CAUTION:
• Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene. Refer to MA-10
.
• Check inside surface of cylinder body for score, rust wear, damage or foreign materials. If any of the
above conditions are observed, replace cylinder body.
• Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
CAUTION:
• Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials are
stuck to sliding surface.
• Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the
above conditions are observed.
Sliding Pin Bolts and Sliding Pin Boots
BRD0041D
PFIA0269E
DI-12
< SERVICE INFORMATION >
COMBINATION METERS
Self-Diagnosis Mode of Combination Meter
INFOID:0000000003533486
SELF-DIAGNOSIS FUNCTION
The following items can be checked during Combination Meter Self-Diagnosis Mode.
• Gauge sweep and present gauge values.
• Illuminates all odometer, fuel, and engine temperature segments.
• Illuminates all micro controlled lamps/LE D's regardless of switch configuration.
• Displays estimated present battery voltage.
• Displays seat belt buckle switch LH status.
HOW TO INITIATE COMBINATION METER SELF- DIAGNOSIS MODE
NOTE:
Once entered, Combination Meter Self-Diagnosis Mode will function with the ignition switch in ON or START.
Combination Meter Self-Diagnosis Mode will exit upon turning the ignition switch to OFF or ACC.
To initiate Combination Meter Self-Diagnosis Mode, refer to the following procedure.
1. Turn the ignition switch ON, while holding the odom eter/trip meter switch for 5 - 8 seconds. When the
diagnosis function is activated the odometer/trip meter will display tESt.
NOTE:
Check combination meter power supply and ground ci rcuit when self-diagnosis mode of combination
meter does not start. Refer to DI-16, "
Power Supply and Ground Circuit Inspection". Replace combination
meter if normal. Refer to IP-10, "
Removal and Installation".
COMBINATION METER SELF-DIAGNOSIS MODE FUNCTIONS
To interpret Combination Meter Self-Diagnosis Mode functions, refer to the following table.
37 W/L Washer fluid level switch ON Washer fluid level low 0
Washer fluid level normal Battery voltage
Te r m i n a l
No. Wire
color Item Condition
Reference value (V)
(Approx.)
Ignition
switch Operation or condition
Event Odometer Display Description of Test/Data Notes:
Odometer/trip meter A/B
switch held from 5 to 8
seconds (or until re-
leased) tESt Initiating self-diagnosis mode
Odometer/trip meter A/B
switch engaged and re-
leased = next test re-
quested rXXXX, FAILReturn to normal opera-
tion of all lamps/LEDs and
displays hex ROM rev. If a
ROM checksum fault ex-
ists, display alternates be-
tween "r XXXX" and
"FAIL".
Next test requested nrXXXX Displays hex ROM rev as
stored in NVM.
Next test requested Sc1XX Displays 8-bit software
configuration value in Hex
format.Bit Coding
7-3 = reserved for future use
2 = TCS/VDC 0 = not present
1 = present
1 = Shift type 0 = Column shift
1 = Floor shift
0 = ICC 0 = not present
1 = present
Next test requested Sc2XX Displays 8-bit software
configuration value in Hex
format.Bit coding
7-0 = Reserved for future use
PRECAUTIONS
GI-3
< SERVICE INFORMATION >
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General PrecautionINFOID:0000000003531471
• Do not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any flammable
materials. Special care should be taken when handling any flam-
mable or poisonous materials, such as gasoline, refrigerant gas,
etc. When working in a pit or other enclosed area, be sure to prop-
erly ventilate the area before working with hazardous materials.
Do not smoke while working on the vehicle.
• Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After jack-
ing up the vehicle, support the vehicle weight with safety stands at
the points designated for proper lifting before working on the vehi-
cle.
These operations should be done on a level surface.
• When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.
• Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
• If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
• Battery posts, terminals and related accessories contain lead and
lead compounds. Wash hands after handling.
• To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
• Dispose of or recycle drained oil or the solvent used for cleaning
parts in an appropriate manner.
• Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel spray
and possibly a fire.
• Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
• Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
• Replace inner and outer races of tapered roller bearings and needle bearings as a set.
• Arrange the disassembled parts in accordance with their assembled locations and sequence.
• Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
• After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
• Use only the fluids and lubricants specified in this manual.
• Use approved bonding agent, sealants or their equivalents when required.
SGI285
SGI231
SEF289H
SGI233
GI-8
< SERVICE INFORMATION >
HOW TO USE THIS MANUAL
Contents
INFOID:0000000003531482
•ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and page
you are searching for.
•A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the
first page of each section by matching it to the section's black tab.
•THE CONTENTS are listed on the first page of each section.
•THE TITLE is indicated on the upper portion of each page and shows the part or system.
•THE PAGE NUMBER of each section consists of two or three letters which designate the particular section
and a number (e.g. “BR-5”).
•THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of
work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle
or transmission, etc. are presented in a step-by-step format where necessary.
ComponentINFOID:0000000003531483
•THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubri-
cation points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to
perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the appro-
priate PARTS CATALOG.
Components shown in an illustration may be identified by a circled number. When this style of illustration is
used, the text description of the components will follow the illustration.
1. Union bolt 2. Copper washer 3. Brake hose
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Piston seal 8. Piston 9. Piston boot
10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt
13. Washer 14. Sliding pin boot 15. Bushing
16. Torque member 17. Inner shim cover 18. Inner shim
19. Inner pad 20. Pad retainer 21. Pad wear sensor
22. Outer pad 23. Outer shim 24. Outer shim cover
1: PBC (Poly Butyl Cuprysil) grease
or silicone-based grease2: Rubber grease : Brake fluid
Refer to GI section for additional symbol definitions.
SFIA2959E
IDX-4
ALPHABETICAL INDEX
Duct and grilles .............................................. ATC-170
DVD - Wiring Diagram ....................................... AV-75
DVD Entertainment System ............................... AV-72
DVD Player ........................................................ AV-73
E
ECM input/output signal ..................... EC-109
, EC-133
ECM power supply ............................. EC-150, EC-475
ECM relay ........................................................ EC-150
ECM/PW - Wiring diagram ............................... EC-476
ECTS - Wiring diagram .................................... EC-220
Electric sunroof .................................................. RF-10
Electric throttle control actuator ......... EC-595, EC-606
Electrical load signal circuit .............................. EC-657
Electrical units location ...................................... PG-65
Electronic ignition (EI) system ........................... EC-27
Engine control circuit diagram ......................... EC-107
Engine control component parts location ........... EC-98
Engine control module (ECM) .......................... EC-479
Engine control system diagram ......................... EC-24
Engine coolant .................................................. CO-10
Engine coolant temperature sensor (ECTS) ... EC-218,
EC-231
Engine fail-safe system ...................................... EC-93
Engine oil ............................................................. LU-8
Engine oil filter replacement ............................. MA-17
Engine oil precautions .......................................... GI-7
Engine oil replacement ..................................... MA-17
Engine removal ................................................. EM-74
Engine room cover ............................................ EM-12
Engine serial number .......................................... GI-50
ETC1 - Wiring diagram .................................... EC-596
ETC2 - Wiring diagram .................................... EC-591
ETC3 - Wiring diagram .................................... EC-602
EVAP canister .................................................... EC-36
EVAP canister purge volume control solenoid valve ....
EC-395
, EC-403
EVAP canister vent control valve ....... EC-410, EC-417
EVAP control system (small leak) diagnosis .. EC-387,
EC-441
, EC-449
EVAP control system pressure sensor .... EC-424, EC-
427, EC-433
EVAP control system purge flow monitoring diagnosis
EC-382
EVAP vapor lines inspection ............................. MA-20
Evaporative emission (EVAP) system ............... EC-33
Evaporator ..................................................... ATC-186
Exhaust manifold .............................................. EM-21
Exhaust system ................................................... EX-3
Exhaust system inspection .................................. EX-3
Expansion valve ............................................. ATC-188
F
F/FOG - Wiring diagram ..................................... LT-56
F/PUMP - Wiring diagram ................................ EC-666
Final drive pre-inspection ................................. FFD-15
Final drive removal and installation .. FFD-12, RFD-13
Flow charts .......................................................... GI-27
Fluid temperature sensor (A/T) ........................ AT-123
Fluids ................................................................ MA-11
Fluorescent leak detector .............................. ATC-189
Fog lamp, front ................................................... LT-54
Fog lamp, front, removal and installation ........... LT-62
Foot lamp ......................................................... LT-111
Freeze frame data ............................... EC-55, EC-121
Front brake solenoid valve ................. AT-139, AT-141
Front bumper ...................................................... EI-13
Front case (Transfer) .......................... TF-149, TF-176
Front combination lamp removal and installation LT-25
Front door ............................. BL-117, BL-121, GW-62
Front Door Trim ................................................... EI-32
Front drive shaft (Transfer) ................. TF-149, TF-176
Front fog lamp .................................................... LT-54
Front fog lamp removal and installation ............. LT-62
Front passenger air bag .................................. SRS-43
Front seat ........................................................... SE-89
Front seat belt ...................................................... SB-3
Front seat belt pre-tensioner ............... SRS-3, SRS-50
Front washer ...................................................... WW-4
Front wiper ......................................................... WW-4
FTS - Wiring diagram ....................................... AT-124
FTTS - Wiring diagram ...................... EC-334, EC-339
Fuel cut control (at no load high engine speed) EC-28
Fuel filter replacement ......................................... FL-5
Fuel gauge ............................................................ DI-5
Fuel injection system (Bank 1) .......... EC-311, EC-322
Fuel injection system (Bank 2) .......... EC-311, EC-322
Fuel injector .................................................... EC-659
Fuel injector and fuel tube ................................. EM-31
Fuel level sensor ................. EC-458, EC-460, EC-462
Fuel line inspection .............................................. FL-4
Fuel precautions ................................................... GI-5
Fuel pressure check .......................................... EC-82
Fuel pressure release ....................................... EC-82
Fuel pump ....................................................... EC-665
Fuel pump and gauge .......................................... FL-5
Fuel system .......................................................... FL-4
Fuel tank ............................................................ FL-10
Fuel tank temperature sensor ........... EC-332, EC-338
Fuel tank vacuum relief valve ........................... EC-36
FUELB1 - Wiring diagram ................. EC-313, EC-324
FUELB2 - Wiring diagram ................. EC-315, EC-326
Fuse ...................................................... PG-17, PG-77
Fuse and fusible link box .................................. PG-77
Fuse block ......................................................... PG-76
Fusible link ............................................ PG-17, PG-77
G
Garage jack and safety stand ............................. GI-42
Gauges ................................................................. DI-5
Generator .......................................................... SC-17
Generic scan tool (GST) ................................. EC-131
Glass ...................................... GW-11, GW-62, GW-65
Glove box lamp ................................................ LT-131
GPS antenna ..................................................... AV-82
IDX-8
ALPHABETICAL INDEX
Three way catalyst ............................................ EM-21
Three way catalyst function (Bank 1) ............... EC-376
Three way catalyst function (Bank 2) ............... EC-376
Three way catalyst precautions ............................ GI-5
Throttle control motor ....................................... EC-601
Throttle control motor relay .............................. EC-589
Throttle position sensor (TPS) .. EC-224, EC-343, EC-
514, EC-516, EC-621
Throttle valve closed position learning ............... EC-80
Tie-rod ............................................................... PS-15
Timing chain ..................................................... EM-37
Tire rotation ....................................................... MA-28
Tire size .............................................................. GI-51
Torque converter installation AT-239, AT-240, AT-243,
AT-244
Torque convertor clutch solenoid valve ... AT-114, AT-
116
Tow truck towing ................................................. GI-44
Towing point ....................................................... GI-45
TPS1 - Wiring diagram .................................... EC-345
TPS2 - Wiring diagram .................................... EC-226
TPS3 - Wiring diagram .................................... EC-623
Traction control system - Wiring diagram ....... BRC-16
Transfer control device ............. TF-75, TF-79, TF-138
Transfer control unit inspection table ................. TF-35
Transfer dropping resistor .................................. TF-89
Transfer fluid temperature sensor TF-103, TF-154, TF-
167
Transfer motor .................................... TF-101, TF-142
Transfer motor relay ........................................ TF-101
Transfer oil replacement ................................... MA-24
Transfer serial number ........................................ GI-50
Transmission serial number ................................ GI-50
Tread-FR&RR (Dimensions) ............................... GI-51
Trim ..................................................................... EI-35
TRNSCV - Wiring diagram .................. BL-130, BL-146
Trouble diagnoses .............................................. GI-11
Turbine revolution sensor ................................ AT-105
TURN - Wiring diagram ...................................... LT-67
Turn signal lamp ................................................. LT-63
Two trip detection logic ...................................... EC-49
Two-pole lift ........................................................ GI-43
V
Vacuum hose (brake system) ............................ BR-20
Vacuum hose drawing (Engine control) ........... EC-106
Valve clearance ................................................ EM-55
Valve guide ....................................................... EM-69
Vanity mirror lamp ............................................. LT-110
VDC (vehicle dynamics control) ........................ BRC-7
VDC -Wiring diagram ...................................... BRC-16
Vehicle identification number .............................. GI-49
Vehicle recovery (freeing a stuck vehicle) .......... GI-45
Vehicle security (theft warning) system ............. BL-67
Vehicle speed sensor (VSS) ............................ EC-464
VEHSEC - Wiring diagram ................................. BL-71
VENT/V - Wiring diagram .................. EC-412, EC-419
VIN registration .................................................. EC-79
Viscosity number (SAE) .................................... MA-12
VSS A/T - Wiring diagram .................. AT-107, AT-109
W
W/ANT - Wiring diagram .................................... AV-59
Wait detection switch ......................................... TF-68
WARN - Wiring diagram ...................................... DI-29
Warning chime .................................................... DI-38
Warning lamps .................................................... DI-28
Washer, front ..................................................... WW-4
Washer, rear .................................................... WW-29
Water pump ...................................................... CO-19
Water temperature gauge ..................................... DI-5
Wheel alignment (front) ..................................... FSU-6
Wheel alignment (rear) ................................... RSU-25
Wheel bearing (front) ........................................ FAX-5
Wheel bearing (rear) ......................................... RAX-5
Wheel hub (rear) ............................................... RAX-5
Wheel size .......................................................... GI-51
Wheelbase (Dimensions) .................................... GI-51
Width (Dimensions) ............................................. GI-51
WINDOW - Wiring diagram .............................. GW-22
Window, door ...................................... GW-62, GW-65
Windshield ....................................................... GW-11
WIP/R - Wiring diagram ................................... WW-33
WIPER - Wiring diagram .................................... WW-8
Wiper, front ........................................................ WW-4
Wiper, rear ....................................................... WW-29
Wiring Diagram (Cell code) list ......................... PG-62
Wiring diagrams .................................................. GI-15
WT-T/WARN - Wiring diagram .......................... WT-11
ENGINE OIL
LU-9
< SERVICE INFORMATION >
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5. Install Tools.
6. Start the engine and warm it up to normal operating temperature.
7. Check the engine oil pressure with engine running under no-load.
Engine oil pressure [Engine oil temperature at 80°C (175°F)]
Unit: kPa (kg/cm2
, psi)
CAUTION:
If the difference is extreme, check the oil passages and oil pump for leaks and blockages.
8. After the inspections, install oil pressure switch as follows:
a. Remove old liquid gasket adhering to oil pressure switch and engine.
b. Apply liquid gasket and tighten oil pressure switch to the specification.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "
Recommended Chemical Prod-
uct and Sealant".
c. After warming up engine, make sure there is no leakage of engine oil with engine running.
Changing Engine OilINFOID:0000000003531556
CAUTION:
• Be careful not to burn yourself, as the engine oil is hot.
• Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with used
engine oil. If skin contact is made, wash thoroughly with soap
or hand cleaner as soon as possible.
1. Remove engine front undercover using power tool.
2. Warm up engine, and check for oil leakage from engine compo-
nents. Refer to LU-8, "
Inspection".
3. Stop engine and wait for 10 minutes.
4. Loosen oil filler cap, then remove drain plug.
5. Drain engine oil.
6. Install drain plug with new washer.
CAUTION:
• Be sure to clean drain plug and install with new washer.
7. Refill with new engine oil. Refer to MA-10, "
Fluids and Lubricants".
Engine oil capacity (Approximate):
Tool number : ST25051001 (J-25695-1)
: ST25052000 (J-25695-2)
WBIA0571E
Engine Speed Approximate Discharge Pressure
Idle speed More than 98 (1.0, 14)
2,000 rpm More than 294 (3.0, 43)
Oil pressure sensor torque : 14.7 N·m (1.5 kg-m, 11 ft-lb)
Oil pan drain plug : 34.3 N·m (3.5 kg-m, 25 ft-lb)
KBIA2498E