CO-68
< ON-VEHICLE REPAIR >[K9K]
WATER OUTLET AND THERMOSTAT ASSEMBLY
WATER OUTLET AND THERMOSTAT ASSEMBLY
Exploded ViewINFOID:0000000001381601
Removal and InstallationINFOID:0000000001381602
REMOVAL
1. Remove battery.
2. Remove engine undercover using power tool.
3. Drain engine coolant. Refer to CO-58, "
Draining".
CAUTION:
Perform when engine is cold.
4. Remove engine cover.
5. Remove air cleaner and air duct assembly. Refer to EM-269, "
Removal and Installation".
6. Remove rear engine slinger. Refer to EM-314, "
Exploded View".
7. Remove vacuum hose.
8. Remove vacuum pump. Refer to EM-280, "
Removal and Installation".
9. Remove radiator upper hose. Refer to CO-62, "
Exploded View".
10. Remove heater hose.
11. Disconnect reservoir tank hose.
12. Remove water outlet.
INSTALLATION
Installation is in the reverse order of removal.
InspectionINFOID:0000000001381603
INSPECTION AFTER REMOVAL
1. O-ring 2. EGR cooler cover 3. Clamp
4. Water pipe 5. Heater hose 6. Clamp
7. Engine coolant temperature sensor 8. O-ring 9. Lock plate
10. Clamp 11. Gasket 12. Water outlet and thermostat assembly
13. Air relief plug
A. To EGR volume control valve housing B. To radiator hose (upper) C. To heater core
E1BIA0027GB
CO-70
< SERVICE DATA AND SPECIFICATIONS (SDS) [K9K]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Periodical Maintenance SpecificationINFOID:0000000001381604
ENGINE COOLANT CAPACITY (APPROXIMATE)
Unit: (Imp qt)
RadiatorINFOID:0000000001381605
Unit: kPa (kg/cm2, psi, bar)
ThermostatINFOID:0000000001381606
Unit: °C (°F)
Engine coolant capacity [With reservoir tank (“MAX” level)] 7.0 (6-1/8)
Reservoir tank engine coolant capacity (At “MAX” level) 0.8 (3/4)
Reservoir tank cap relief pressure 130 - 150 (1.33 - 1.53, 18.9 - 21.8, 1.3 - 1.5)
Leakage testing pressure 10 (0.10, 1.5, 0.1)
Temperature of start opening 89 (192)
Temperature of end opening 97 - 101 (207 - 214)
DLK-5
C
D
E
F
G
H
I
J
L
MA
B
DLK
N
O
P
RADIATOR CORE SUPPORT .........................219
Removal and Installation .......................................219
FRONT FENDER ..............................................221
Removal and Installation .......................................221
DOOR ...............................................................222
Fitting Adjustment .................................................222
Removal and Installation .......................................225
FUEL FILLER LID OPENER ............................228
Removal and Installation of Fuel Filler Lid Opener ..228
FRONT DOOR LOCK .......................................230
Component Parts Location ....................................230
Removal and Installation .......................................230
REAR DOOR LOCK .........................................233
Component Parts Location ....................................233
Removal and Installation .......................................233
BACK DOOR LOCK .........................................236
Removal and Installation .......................................236
TRUNK LID .......................................................237
Fitting Adjustment .................................................237
Trunk Lid Assembly ...............................................237
Trunk Lid Lock .......................................................238
Trunk Lid Striker ....................................................238
WITH I-KEY & SUPER LOCK
BASIC INSPECTION .................................
240
DIAGNOSIS AND REPAIR WORKFLOW .......240
Work Flow .............................................................240
INSPECTION AND ADJUSTMENT ..................243
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT ......................................................
243
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Description ..............................
243
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Special Repair Requirement ...
243
FUNCTION DIAGNOSIS ............................244
DOOR LOCK FUNCTION ................................244
DOOR LOCK AND UNLOCK SWITCH ...................244
DOOR LOCK AND UNLOCK SWITCH : System
Diagram .................................................................
244
DOOR LOCK AND UNLOCK SWITCH : System
Description ............................................................
244
DOOR LOCK AND UNLOCK SWITCH :
Component Parts Location ..................................
246
DOOR LOCK AND UNLOCK SWITCH :
Component Description ........................................
247
INTELLIGENT KEY .................................................247
INTELLIGENT KEY : System Diagram .................247
INTELLIGENT KEY : System Description .............247
INTELLIGENT KEY : Component Parts Location ..249
INTELLIGENT KEY : Component Description ......251
DOOR REQUEST SWITCH .....................................251
DOOR REQUEST SWITCH : System Diagram .....251
DOOR REQUEST SWITCH : System Description ..251
DOOR REQUEST SWITCH :
Component Parts Location ..................................
253
DOOR REQUEST SWITCH :
Component Description ........................................
255
KEY REMINDER ......................................................255
KEY REMINDER : System Diagram ......................255
KEY REMINDER : System Description .................255
KEY REMINDER : Component Parts Location ....257
KEY REMINDER : Component Description ..........259
BACK DOOR OPENER FUNCTION ...............260
BACK DOOR OPENER SWITCH ............................260
BACK DOOR OPENER SWITCH : System Dia-
gram ......................................................................
260
BACK DOOR OPENER SWITCH : System De-
scription .................................................................
260
BACK DOOR OPENER SWITCH :
Component Parts Location ..................................
260
BACK DOOR OPENER SWITCH :
Component Description ........................................
261
TRUNK LID OPENER .....................................262
TRUNK LID OPENER SWITCH ...............................262
TRUNK LID OPENER SWITCH : System Diagram
..
262
TRUNK LID OPENER SWITCH : System Descrip-
tion .........................................................................
262
TRUNK LID OPENER SWITCH :
Component Parts Location ..................................
262
TRUNK LID OPENER SWITCH :
Component Description ........................................
263
WARNING FUNCTION ....................................264
System Diagram ....................................................264
System Description ................................................264
Component Parts Location ..................................267
Component Description ........................................269
HAZARD AND BUZZER REMINDER FUNC-
TION ................................................................
270
System Diagram ....................................................270
System Description ................................................270
Component Parts Location ..................................272
Component Description ........................................274
DIAGNOSIS SYSTEM (BCM) .........................275
COMMON ITEM .......................................................275
COMMON ITEM : CONSULT-III Function (BCM -
COMMON ITEM) ...................................................
275
DOOR LOCK ............................................................275
DLK-9
C
D
E
F
G
H
I
J
L
MA
B
DLK
N
O
P
PREPARATION .........................................439
PREPARATION ................................................439
Commercial Service Tools ....................................439
ON-VEHICLE MAINTENANCE ..................440
PRE-INSPECTION FOR DIAGNOSTIC ...........440
Basic Inspection ....................................................440
REMOVAL AND INSTALLATION .............442
HOOD ...............................................................442
Fitting Adjustment .................................................442
Removal and Installation .......................................443
Removal and Installation of Hood Lock Control ....444
Hood Lock Control Inspection ...............................446
RADIATOR CORE SUPPORT .........................448
Removal and Installation .......................................448
FRONT FENDER ..............................................450
Removal and Installation .......................................450
DOOR ...............................................................451
Fitting Adjustment .................................................451
Removal and Installation .......................................454
FUEL FILLER LID OPENER ............................457
Removal and Installation of Fuel Filler Lid Opener ..457
FRONT DOOR LOCK .......................................459
Component Parts Location ....................................459
Removal and Installation .......................................459
REAR DOOR LOCK .........................................462
Component Parts Location ....................................462
Removal and Installation .......................................462
BACK DOOR LOCK .........................................465
Removal and Installation .......................................465
TRUNK LID .......................................................466
Fitting Adjustment .................................................466
Trunk Lid Assembly ...............................................466
Trunk Lid Lock .......................................................467
Trunk Lid Striker ....................................................467
WITHOUT I-KEY & SUPER LOCK
BASIC INSPECTION .................................
469
DIAGNOSIS AND REPAIR WORKFLOW .......469
Work Flow .............................................................469
INSPECTION AND ADJUSTMENT ..................472
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT ......................................................
472
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Description ..............................
472
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Special Repair Requirement ...
472
FUNCTION DIAGNOSIS ............................473
DOOR LOCK FUNCTION ...............................473
DOOR LOCK AND UNLOCK SWITCH ...................473
DOOR LOCK AND UNLOCK SWITCH : System
Diagram .................................................................
473
DOOR LOCK AND UNLOCK SWITCH : System
Description .............................................................
473
DOOR LOCK AND UNLOCK SWITCH :
Component Parts Location ..................................
474
DOOR LOCK AND UNLOCK SWITCH :
Component Description ........................................
475
REMOTE KEYLESS ENTRY ...................................475
REMOTE KEYLESS ENTRY : System Diagram ...475
REMOTE KEYLESS ENTRY : System Descrip-
tion .........................................................................
475
REMOTE KEYLESS ENTRY :
Component Parts Location ..................................
476
REMOTE KEYLESS ENTRY :
Component Description ........................................
477
BACK DOOR OPENER FUNCTION ...............478
BACK DOOR OPENER SWITCH ............................478
BACK DOOR OPENER SWITCH : System Dia-
gram ......................................................................
478
BACK DOOR OPENER SWITCH : System De-
scription .................................................................
478
BACK DOOR OPENER SWITCH :
Component Parts Location ..................................
478
BACK DOOR OPENER SWITCH :
Component Description ........................................
479
TRUNK LID OPENER .....................................480
TRUNK LID OPENER SWITCH ...............................480
TRUNK LID OPENER SWITCH : System Diagram
..
480
TRUNK LID OPENER SWITCH : System Descrip-
tion .........................................................................
480
TRUNK LID OPENER SWITCH :
Component Parts Location ..................................
480
TRUNK LID OPENER SWITCH :
Component Description ........................................
481
WARNING FUNCTION ....................................482
System Diagram ....................................................482
System Description ................................................482
Component Parts Location ..................................483
Component Description ........................................484
HAZARD REMINDER FUNCTION ..................485
System Diagram ....................................................485
System Description ................................................485
Component Parts Location ..................................486
Component Description ........................................487
DIAGNOSIS SYSTEM (BCM) .........................488
COMMON ITEM .......................................................488
DLK-11
C
D
E
F
G
H
I
J
L
MA
B
DLK
N
O
P BACK DOOR : Description ....................................
534
BACK DOOR : Component Function Check .......534
BACK DOOR : Diagnosis Procedure ....................534
BACK DOOR : Component Inspection ..................536
TRUNK LID OPENER ACTUATOR .................537
Description ............................................................537
Component Function Check ................................537
Diagnosis Procedure .............................................537
Component Inspection ..........................................538
BUZZER (COMBINATION METER) .................540
Description ............................................................540
Component Function Check ................................540
Diagnosis Procedure .............................................540
HAZARD WARNING LAMPS ...........................541
Description ............................................................541
Component Function Check ................................541
Diagnosis Procedure .............................................541
VEHICLE SPEED SIGNAL CIRCUIT ...............542
Description ............................................................542
Component Function Check ................................542
Diagnosis Procedure .............................................542
KEYFOB BATTERY AND FUNCTION .............543
Description ............................................................543
Component Function Check ................................543
Diagnosis Procedure .............................................543
Component Inspection ..........................................543
Special Repair Requirement .................................543
ECU DIAGNOSIS .......................................544
BCM (BODY CONTROL MODULE) .................544
Reference Value ...................................................544
Wiring Diagram - POWER DOOR LOCK SYSTEM
- .............................................................................
544
Wiring Diagram - REMOTE KEYLESS ENTRY
SYSTEM - .............................................................
552
Wiring Diagram - BACK DOOR OPENER SYS-
TEM - ....................................................................
558
Wiring Diagram - TRUNK LID OPENER SYSTEM
- .............................................................................
562
Fail Safe ...............................................................564
DTC Inspection Priority Chart .............................565
DTC Index ............................................................565
SYMPTOM DIAGNOSIS ............................567
DOOR LOCK FUNCTION SYMPTOMS ...........567
DOOR LOCK AND UNLOCK SWITCH ...................567
DOOR LOCK AND UNLOCK SWITCH : Symptom
Table .....................................................................
567
KEYFOB ..................................................................567
KEYFOB : Symptom Table ...................................567
BACK DOOR OPEN FUNCTION SYMPTOMS
..
569
BACK DOOR OPENER SWITCH ............................569
BACK DOOR OPENER SWITCH : Symptom Ta-
ble ..........................................................................
569
TRUNK OPEN FUNCTION SYMPTOMS ........570
TRUNK LID OPENER SWITCH ...............................570
TRUNK LID OPENER SWITCH : Symptom Table ..570
WARNING FUNCTION SYMPTOMS ..............571
BACK DOOR ...........................................................571
BACK DOOR : Symptom Table .............................571
HAZARD REMINDER FUNCTION ..................572
HAZARD WARNING LAMP .....................................572
HAZARD WARNING LAMP : Symptom Table ......572
SQUEAK AND RATTLE TROUBLE DIAG-
NOSES ............................................................
573
Work Flow ..............................................................573
Inspection Procedure .............................................575
Diagnostic Worksheet ............................................577
PRECAUTION ............................................579
PRECAUTIONS ...............................................579
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...............................................................
579
Procedure without Cowl Top Cover ....................579
Steering Wheel Rotation after Battery Disconn
ect ..........................................................................
579
Work ......................................................................580
PREPARATION .........................................581
PREPARATION ...............................................581
Commercial Service Tool ......................................581
ON-VEHICLE MAINTENANCE ..................582
PRE-INSPECTION FOR DIAGNOSTIC ..........582
Basic Inspection ....................................................582
REMOVAL AND INSTALLATION .............583
HOOD ..............................................................583
Fitting Adjustment ..................................................583
Removal and Installation .......................................584
Removal and Installation of Hood Lock Control ....585
Hood Lock Control Inspection ...............................587
RADIATOR CORE SUPPORT ........................589
Removal and Installation .......................................589
FRONT FENDER .............................................591
Removal and Installation .......................................591
DOOR ..............................................................592
Fitting Adjustment ..................................................592
Removal and Installation .......................................595
DLK-14
REAR LH ..................................................................681
REAR LH : Description ..........................................681
REAR LH : Component Function Check ..............681
REAR LH : Diagnosis Procedure ...........................681
REAR RH .................................................................682
REAR RH : Description .........................................682
REAR RH : Component Function Check .............682
REAR RH : Diagnosis Procedure ..........................683
TRUNK LID OPENER ACTUATOR .................685
Description .............................................................685
Component Function Check ................................685
Diagnosis Procedure .............................................685
Component Inspection ...........................................686
BUZZER (COMBINATION METER) ................688
Description .............................................................688
Component Function Check ................................688
Diagnosis Procedure .............................................688
HAZARD WARNING LAMPS ..........................689
Description .............................................................689
Component Function Check ................................689
Diagnosis Procedure .............................................689
VEHICLE SPEED SIGNAL CIRCUIT ..............690
Description .............................................................690
Component Function Check ................................690
Diagnosis Procedure .............................................690
KEYFOB BATTERY AND FUNCTION ............691
Description .............................................................691
Component Function Check ................................691
Diagnosis Procedure .............................................691
Component Inspection ...........................................691
Special Repair Requirement ..................................691
ECU DIAGNOSIS .......................................692
BCM (BODY CONTROL MODULE) ................692
Reference Value ....................................................692
Wiring Diagram - POWER DOOR LOCK SYSTEM
- .............................................................................
693
Wiring Diagram - REMOTE KEYLESS ENTRY
SYSTEM - ..............................................................
703
Wiring Diagram - BACK DOOR OPENER SYS-
TEM - .....................................................................
709
Wiring Diagram - TRUNK LID OPENER SYSTEM
- .............................................................................
713
Fail Safe ................................................................715
DTC Inspection Priority Chart .............................716
DTC Index .............................................................716
SYMPTOM DIAGNOSIS ............................718
DOOR LOCK FUNCTION SYMPTOMS ..........718
DOOR LOCK AND UNLOCK SWITCH ...................718
DOOR LOCK AND UNLOCK SWITCH : Symptom
Table ......................................................................
718
KEYFOB ..................................................................718
KEYFOB : Symptom Table ...................................719
BACK DOOR OPEN FUNCTION SYMPTOMS
..
720
BACK DOOR OPENER SWITCH ...........................720
BACK DOOR OPENER SWITCH : Symptom Ta-
ble .........................................................................
720
TRUNK OPEN FUNCTION SYMPTOMS .........721
TRUNK LID OPENER SWITCH ..............................721
TRUNK LID OPENER SWITCH : Symptom Table .721
WARNING FUNCTION SYMPTOMS ...............722
BACK DOOR ...........................................................722
BACK DOOR : Symptom Table ............................722
HAZARD REMINDER FUNCTION ...................723
HAZARD WARNING LAMP ....................................723
HAZARD WARNING LAMP : Symptom Table ......723
SQUEAK AND RATTLE TROUBLE DIAG-
NOSES ..............................................................
724
Work Flow .............................................................724
Inspection Procedure ............................................726
Diagnostic Worksheet ...........................................728
PRECAUTION ...........................................730
PRECAUTIONS ................................................730
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...............................................................
730
Procedure without Cowl Top Cover ...................730
Steering Wheel Rotation after Battery Disconn
ect .........................................................................
730
Work ......................................................................731
PREPARATION .........................................732
PREPARATION ................................................732
Commercial Service Tool ......................................732
ON-VEHICLE MAINTENANCE .................733
PRE-INSPECTION FOR DIAGNOSTIC ...........733
Basic Inspection ....................................................733
REMOVAL AND INSTALLATION .............734
HOOD ...............................................................734
Fitting Adjustment .................................................734
Removal and Installation .......................................735
Removal and Installation of Hood Lock Control ....736
Hood Lock Control Inspection ...............................738
RADIATOR CORE SUPPORT .........................740
Removal and Installation .......................................740
SQUEAK AND RATTLE TROUBLE DIAGNOSES
DLK-205
< SYMPTOM DIAGNOSIS >[WITH I-KEY, WITHOUT SUPER LOCK]
C
D
E
F
G
H
I
J
L
MA
B
DLK
N
O
P
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS
When isolating seat noise it is important to note the position the seat is in and the load placed on the seat
when the noise is present. These conditions should be duplicated when verifying and isolating the cause of
the noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. Rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
DLK-214
< REMOVAL AND INSTALLATION >[WITH I-KEY, WITHOUT SUPER LOCK]
HOOD
4. Press the hood lightly with [approx. 29 N (3 kg] of force and adjust A and B as shown.
5. After adjustment tighten lock bolts to the specified torque.
6. Install the front grille. Refer to EXT-19, "
Removal and Installation".
Removal and InstallationINFOID:0000000001315832
HOOD ASSEMBLY
Removal
1. Hood striker 2. Primary latch 3. Secondary striker
4. Secondary latch
A : 20 mm (0.79 in)
B : 6.8 mm (0.268 in) min.
PIIB5794E
1. Hood hinge 2. Hood stay 3. Radiator core seal rubber
4. Hood assembly 5. Hood insulator 6. Hood stay holder
PIIB2528J