EM-252
< PRECAUTION >[K9K]
PRECAUTIONS
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-III.
Precaution for Drain CoolantINFOID:0000000001381450
Drain coolant when engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000001381451
Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and DisassemblyINFOID:0000000001381452
When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precaution for Inspection, Repair and ReplacementINFOID:0000000001381453
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000001381454
Use torque wrench to tighten bolts or nuts to specified value.
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly same as specified.
Replace with new gasket, packing, oil seal or O-ring.
Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assemble, spread the oil on sliding surfaces well.
Release air within route when refilling after draining coolant.
Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped).
Then make sure that there are no leaks at fuel line connections.
After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for
leakage.
Parts Requiring Angular TighteningINFOID:0000000001381455
Use an angle wrench for the final tightening of the following engine parts.
- Cylinder head bolts
- Lower cylinder block bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.
EM-272
< ON-VEHICLE REPAIR >[K9K]
EGR SYSTEM
EGR SYSTEM
Exploded ViewINFOID:0000000001381474
Removal and InstallationINFOID:0000000001381475
REMOVAL
1. Remove battery ground cable.
2. Remove engine undercover using power tool.
3. Drain engine coolant. Refer to CO-58, "
Draining".
4. Remove lower radiator hose. Refer to CO-62, "
Exploded View".
5. Remove cowl top cover and cowl top extension assembly. Refer to EXT-20, "
Removal and Installation".
6. Remove air cleaner and air duct assembly. Refer to EM-269, "
Removal and Installation".
7. Remove charge air cooler inlet tubes at EGR assembly. Refer to EM-270, "
Exploded View".
8. Disconnect EGR volume control valve and electronic throttle control actuator connectors.
9. Disconnect heater hoses from EGR cooler cover.
10. Remove EGR cooler cover.
11. Remove front engine slinger.
12. Remove air inlet tube.
13. Remove RH fender protector. Refer to EXT-22, "
Removal and Installation".
1. Air inlet tube 2. Engine slinger 3. O-ring
4. Bracket 5. EGR tube 6. Gasket
7. EGR cooler 8. Gasket 9. EGR volume control valve
10. Gasket 11. EGR volume control valve housing 12. Clamp
13. EGR tube 14. Gasket 15. Gasket
16. Electronic throttle control actuator 17. O-ring 18. EGR cooler cover
A. To intake manifold B. To exhaust manifold
E1BIA0025GB
GLOW PLUG
EM-279
< ON-VEHICLE REPAIR >[K9K]
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GLOW PLUG
Exploded ViewINFOID:0000000001381485
Removal and InstallationINFOID:0000000001381486
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Disconnect battery ground cable.
2. Remove air duct (inlet). Refer to EM-269, "
Exploded View".
3. Remove engine cover. Refer to EM-270, "
Removal and Installation".
4. Remove charge air cooler tubes and hoses at EGR unit and electronic throttle control actuator. Refer to
EM-270, "
Exploded View".
5. Remove high pressure pipes protection cover. Refer to EM-281, "
Exploded View".
6. Disconnect harness connector from glow plug.
7. Remove glow plug.
CAUTION:
When removing or installing, do not use such tools as an air impact wrench.
Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a suitable tool.
2. Install glow plug.
3. Installation is in the reverse order of removal.
1. Glow plug
: Engine front
E1BIA0005GB
: 15.0 N·m (1.5 kg-m, 11 ft-lb)
EM-280
< ON-VEHICLE REPAIR >[K9K]
VACUUM PUMP
VACUUM PUMP
Exploded ViewINFOID:0000000001381487
Removal and InstallationINFOID:0000000001381488
REMOVAL
1. Remove engine cover. Refer to EM-270, "Removal and Installation".
2. Remove air duct (inlet). Refer to EM-269, "
Exploded View".
3. Remove battery. Refer to PG-6, "
Removal and Installation".
4. Remove the air duct (suction). Refer to EM-269, "
Exploded View".
5. Remove blow-by hose.
6. Remove electronic throttle control actuator. Refer to EM-272, "
Exploded View".
7. Disconnect vacuum hose from vacuum pump.
8. Remove vacuum pump.
INSTALLATION
Installation is in the reverse order of removal.
InspectionINFOID:0000000001381489
INSPECTION BEFORE REMOVAL
1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connec-
tor.
2. Start engine and measure generated vacuum at idle speed.
1. Vacuum pump 2. Gasket
A. To vacuum hose
: Engine front
E1BIA0007GB
Standard
: – 86.6 to – 101.3 kPa (– 866 to – 1,013 mbar, – 650 to – 760 mmHg, – 25.59 to – 29.92 inHg)
ROCKER COVER
EM-289
< ON-VEHICLE REPAIR >[K9K]
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ROCKER COVER
Exploded ViewINFOID:0000000001381497
Removal and InstallationINFOID:0000000001381498
REMOVAL
1. Remove engine cover.
2. Remove air duct (inlet). Refer to EM-269, "
Exploded View".
3. Remove air duct (suction). Refer to EM-269, "
Exploded View".
4. Remove charge air cooler pipes and hoses. Refer to EM-270, "
Exploded View".
5. Disconnect and remove camshaft position sensor.
6. Remove fuel hose shield.
7. Disconnect electronic throttle control actuator. Refer to EM-272, "
Exploded View".
8. Remove blow-by hose.
9. Remove high pressure pipes protection cover (upper).
10. Unclip fuel injector spill hose from rocker cover.
11. Unclip timing belt upper cover.
12. Remove rocker cover.
NOTE:
Loosen bolts in the reverse order as shown.
INSTALLATION
1. Install new gasket to rocker cover.
1. Oil filler cap 2. Rocker cover 3. Gasket
4. Camshaft position sensor
E1BIA0006GB
E1BIA0048ZZ
EM-298
< ON-VEHICLE REPAIR >[K9K]
CAMSHAFT
CAMSHAFT
Exploded ViewINFOID:0000000001381501
Removal and InstallationINFOID:0000000001381502
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove front wheel RH. Refer to WT-6, "Rotation".
2. Remove fender protector RH. Refer to EXT-22, "
Removal and Installation".
3. Remove rocker cover. Refer to EM-289, "
Removal and Installation".
4. Remove electronic throttle control actuator. Refer to EM-272, "
Exploded View".
5. Remove vacuum pump. Refer to EM-280, "
Removal and Installation".
6. Remove drive belt. Refer to EM-263, "
Removal and Installation".
7. Support the engine using suitable tool.
CAUTION:
Put a piece of wood or something similar as supporting surface to secure a completely stable con-
dition.
8. Remove timing belt. Refer to EM-291, "
Removal and Installation".
9. Remove camshaft brackets.
10. Remove camshaft.
11. Remove valve lifter.
INSTALLATION
1. Camshaft sprocket stud bolt 2. Camshaft sprocket 3. Oil seal
4. Camshaft bracket 5. Camshaft 6. Cylinder head suspended bracket
7. Valve lifter 8. Cap 9. Cylinder head
A. 30.0 N·m (3.1 kg-m, 22 ft-lb) and 86 degrees
E1BIA0023GB
EXL-2
FLASHER : CONSULT-III Function (BCM -
FLASHER) ..............................................................
27
COMB SW .................................................................28
COMB SW : CONSULT-III Function (BCM -
COMB SW) .............................................................
28
BATTERY SAVER ....................................................28
BATTERY SAVER : CONSULT-III Function (BCM
- BATTERY SAVER) ..............................................
28
DIAGNOSIS SYSTEM (IPDM E/R) ....................30
CONSULT - III Function (IPDM E/R) ......................30
DIAGNOSIS SYSTEM (HEADLAMP LEVEL-
IZER) ..................................................................
31
CONSULT-III Function ...........................................31
COMPONENT DIAGNOSIS ........................32
POWER SUPPLY AND GROUND CIRCUIT .....32
BCM (BODY CONTROL MODULE) .........................32
BCM (BODY CONTROL MODULE) : Diagnosis
Procedure ...............................................................
32
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) .............................
32
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) : Diagnosis Pro-
cedure .....................................................................
32
HEADLAMP (HI) CIRCUIT ................................33
HEADLAMP (HALOGEN) .........................................33
HEADLAMP (HALOGEN) : Description ..................33
HEADLAMP (HALOGEN) : Component Function
Check .....................................................................
33
HEADLAMP (HALOGEN) : Diagnosis Procedure ...33
HEADLAMP (XENON) ..............................................34
HEADLAMP (XENON) : Description .......................34
HEADLAMP (XENON) : Component Function
Check .....................................................................
34
HEADLAMP (XENON) : Diagnosis Procedure .......35
HEADLAMP (LO) CIRCUIT ...............................37
HEADLAMP (HALOGEN) .........................................37
HEADLAMP (HALOGEN) : Description ..................37
HEADLAMP (HALOGEN) : Component Function
Check .....................................................................
37
HEADLAMP (HALOGEN) : Diagnosis Procedure ...37
HEADLAMP (XENON) ..............................................38
HEADLAMP (XENON) : Description .......................38
HEADLAMP (XENON) : Component Function
Check .....................................................................
38
HEADLAMP (XENON) : Diagnosis Procedure .......39
FRONT FOG LAMP CIRCUIT ...........................41
Description ..............................................................41
Component Function Check ...................................41
Diagnosis Procedure ...............................................41
REAR FOG LAMP CIRCUIT .............................43
Description ..............................................................43
Component Function Check ...................................43
Diagnosis Procedure ...............................................43
PARKING LAMP CIRCUIT ................................46
WITH DAYTIME LIGHT SYSTEM .............................46
WITH DAYTIME LIGHT SYSTEM : Description .....46
WITH DAYTIME LIGHT SYSTEM : Component
Function Check .......................................................
46
WITH DAYTIME LIGHT SYSTEM : Diagnosis Pro-
cedure .....................................................................
46
WITHOUT DAYTIME LIGHT SYSTEM .....................48
WITHOUT DAYTIME LIGHT SYSTEM : Descrip-
tion ..........................................................................
48
WITHOUT DAYTIME LIGHT SYSTEM : Compo-
nent Function Check ...............................................
48
WITHOUT DAYTIME LIGHT SYSTEM : Diagno-
sis Procedure ..........................................................
49
TURN SIGNAL LAMP CIRCUIT ........................52
Description ..............................................................52
Component Function Check ...................................52
Diagnosis Procedure ...............................................52
LIGHT & RAIN SENSOR ...................................55
Description ..............................................................55
Component Function Check ...................................55
Diagnosis Procedure ...............................................55
HEADLAMP AIMER SWITCH ...........................57
Description ..............................................................57
Diagnosis Procedure ...............................................57
HEADLAMP (HALOGEN) .................................58
Wiring Diagram .......................................................58
HEADLAMP (XENON) .......................................59
Wiring Diagram .......................................................59
AUTO LIGHT SYSTEM .....................................60
Wiring Diagram .......................................................60
HEADLAMP AIMING SYSTEM (MANUAL) ......61
Wiring Diagram .......................................................61
HEADLAMP AIMING SYSTEM (AUTOMAT-
IC) ......................................................................
62
Wiring Diagram .......................................................62
DAYTIME LIGHT SYSTEM ...............................63
Wiring Diagram .......................................................63
FRONT FOG LAMP ...........................................64
Wiring Diagram .......................................................64
REAR FOG LAMP .............................................65
Wiring Diagram .......................................................65
EXL-3
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TURN SIGNAL AND HAZARD WARNING
LAMPS ...............................................................
66
Wiring Diagram .......................................................66
PARKING, LICENSE PLATE AND TAIL
LAMPS ...............................................................
67
WITH DAYTIME LIGHT SYSTEM .............................67
WITH DAYTIME LIGHT SYSTEM : Wiring Dia-
gram ........................................................................
67
WITHOUT DAYTIME LIGHT SYSTEM ......................67
WITHOUT DAYTIME LIGHT SYSTEM : Wiring Di-
agram ......................................................................
68
STOP LAMP .......................................................69
Wiring Diagram .......................................................69
BACK-UP LAMP ................................................70
Wiring Diagram .......................................................70
ECU DIAGNOSIS .........................................71
BCM (BODY CONTROL MODULE) ...................71
Description ..............................................................71
IPDM E/R (INTELLIGENT POWER DISTRI-
BUTION MODULE ENGINE ROOM) .................
72
Description ..............................................................72
SYMPTOM DIAGNOSIS ..............................73
EXTERIOR LIGHTING SYSTEM SYMPTOMS ....73
Symptom Table .......................................................73
NORMAL OPERATING CONDITION .................75
Description ..............................................................75
BOTH SIDE HEADLAMPS DO NOT SWITCH
TO HIGH BEAM .................................................
76
Description ..............................................................76
Diagnosis Procedure ...............................................76
BOTH SIDE HEADLAMPS (LO) ARE NOT
TURNED ON .......................................................
77
Description ..............................................................77
Diagnosis Procedure ...............................................77
PARKING, LICENSE PLATE AND TAIL
LAMPS ARE NOT TURNED ON ........................
78
Description ..............................................................78
Diagnosis Procedure ...............................................78
BOTH SIDE FRONT FOG LAMPS ARE NOT
TURNED ON .......................................................
79
Description ..............................................................79
Diagnosis Procedure ...............................................79
PRECAUTION ..............................................80
PRECAUTIONS ..................................................80
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
80
ON-VEHICLE MAINTENANCE ....................81
HEADLAMP ......................................................81
Aiming Adjustment ...................................................81
FRONT FOG LAMP ..........................................83
Aiming Adjustment ...................................................83
ON-VEHICLE REPAIR .................................84
HEADLAMP ......................................................84
Bulb Replacement ...................................................84
Removal and Installation .........................................84
Disassembly and Assembly - Halogen ....................85
Disassembly and Assembly - Xenon .......................86
FRONT FOG LAMP ..........................................87
Bulb Replacement ...................................................87
Removal and Installation .........................................87
HEADLAMP AIMING CONTROL ......................88
Removal and Installation of Headlamp Aiming
Switch ......................................................................
88
Removal and Installation of Height Sensor .............89
AUTO LIGHT SYSTEM .....................................91
Removal and Installation of Light and Rain Sensor
....
91
SIDE TURN SIGNAL LAMP ..............................92
Bulb Replacement ...................................................92
Removal and Installation .........................................92
REAR COMBINATION LAMP ...........................93
Bulb Replacement ...................................................93
Removal and Installation .........................................93
Disassembly and Assembly .....................................93
HIGH-MOUNTED STOP LAMP ........................96
Bulb Replacement ...................................................96
Removal and Installation .........................................96
LICENSE PLATE LAMP ...................................98
Bulb Replacement ...................................................98
Removal and Installation .........................................98
REAR FOG LAMP ...........................................100
Bulb Replacement .................................................100
Removal and Installation .......................................100
LIGHTING & TURN SIGNAL SWITCH ...........101
Removal and Installation .......................................101
HAZARD SWITCH ..........................................102
Removal and Installation .......................................102
SERVICE DATA AND SPECIFICATIONS
(SDS) ..........................................................
103