FRONT BUMPER
EXT-13
< ON-VEHICLE REPAIR >
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7. Pull bumper fascia side toward the vehicle side to disengage the
bumper fascia from bumper side brackets (LH/RH).
8. Disengage front bumper fascia from bumper brackets (A) (LH/
RH).
9. Remove bumper fascia assembly.
CAUTION:
When removing bumper fascia, 2 workers are required so as to prevent it from dropping.
10. Remove the following parts after removing bumper fascia.
License plate bracket
Front bumper retainer
Front bumper molding (LH/RH)
Headlamp washer nozzle (LH/RH). Refer to WW-102, "
Removal and Installation".
Front fog lamps (LH/RH). Refer to EXL-183, "
Removal and Installation".
11. Remove bumper energy absorber.
12. Remove bumper reinforcement mounting nuts, and then remove bumper reinforcement with power tool.
13. Remove bumper stay (LH/RH) mounting bolts, and then remove bumper stay (LH/RH).
INSTALLATION
Install in the reverse order of removal.
NOTE:
After installing, perform fitting adjustment.
: Pawl
JMKIA2520ZZ
JMKIA2521ZZ
JMKIA2550ZZ
Portion Clearance Flush
Front bumper – Front grille A – A 3.5 – 8.5 mm (0.138 – 0.335 in) —
Front bumper – Hood B – B 3.7 – 8.3 mm (0.146 – 0.327 in) —
HOW TO USE THIS MANUAL
GI-5
< HOW TO USE THIS MANUAL >
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SYMBOLS
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
SAIA0749E
TIGHTENING TORQUE OF STANDARD BOLTS
GI-15
< HOW TO USE THIS MANUAL >
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The parts with aluminum or the cast iron washer surface/thread surface are excluded.
NEW STANDARD BASED ON ISO
CAUTION:
1. Use tightening torque with lubricant for the new standard bolts/nuts in principle. Friction coeffi-
cient stabilizer is applied to the new standard bolts/nuts.
2. However, use tightening torque without lubricant for the following cases. Friction coefficient stabi-
lizer is not applied to the following bolts/nuts.
- Grade 4.8, M6 size bolt, Conical spring washer installed
- Paint removing nut (Size M6 and M8) for fixing with weld bolt
Grade
(Strength
grade)Bolt
sizeBolt di-
ameter
mmHexagonal
width
across flats
mmPitch
mmTightening torque
Hexagon head bolt Hexagon flange bolt
N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb
4.8
(Without
lubricant)M6 6.0 10 1.0 5.5 0.56 4 49 7 0.71 5 62
M8 8.0 131.25 13.5 1.4 10 — 17 1.7 13 —
1.0 13.5 1.4 10 — 17 1.7 13 —
M10 10.0 161.5 282.921 — 353.626 —
1.25 28 2.9 21 — 35 3.6 26 —
M12 12.0 181.75 45 4.6 33 — 55 5.6 41 —
1.25 45 4.6 33 — 65 6.6 48 —
M14 14.0 21 1.5 80 8.2 59 — 100 10 74 —
4.8
(With lu-
bricant)M6 6.0 10 1.0 40.413 355.50.564 49
M8 8.0 131.25 11 1.1 8 — 13.5 1.4 10 —
1.0 11 1.1 8 — 13.5 1.4 10 —
M10 10.0 161.5 222.216 — 282.921 —
1.25 22 2.2 16 — 28 2.9 21 —
M12 12.0 181.75 35 3.6 26 — 45 4.6 33 —
1.25 35 3.6 26 — 45 4.6 33 —
M14 14.0 21 1.5 65 6.6 48 — 80 8.2 59 —
8.8
(With lu-
bricant)M6 6.0 10 1.0 8 0.82 6 71 10 1.0 7 89
M8 8.0 131.25 21 2.1 15 — 25 2.6 18 —
1.0 212.115 — 252.618 —
M10 10.0 161.5 404.130 — 505.137 —
1.25 40 4.1 30 — 50 5.1 37 —
M12 12.0 181.75 70 7.1 52 — 85 8.7 63 —
1.25 70 7.1 52 — 85 8.7 63 —
M14 14.0 21 1.5 120 12 89 — 140 14 103 —
10.9
(With lu-
bricant)M6 6.0 10 1.0 10 1.0 7 89 12 1.2 9 106
M8 8.0 131.25 27 2.8 20 — 32 3.3 24 —
1.0 272.820 — 323.324 —
M10 10.0 161.5 555.641 — 656.648 —
1.25 55 5.6 41 — 65 6.6 48 —
M12 12.0 181.75 95 9.7 70 — 110 11 81 —
1.25 95 9.7 70 — 110 11 81 —
M14 14.0 21 1.5 160 16 118 — 180 18 133 —
GI-26
< PRECAUTION >
PRECAUTIONS
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.
To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
Dispose of 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.
Use hand tools, power tools (disassembly only) and recommended
special tools where specified for safe and efficient service repairs.
When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate covers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
SEF289H
SGI233
PBIC0190E
SGI234
HA-32
< ON-VEHICLE MAINTENANCE >
FLUORESCENT LEAK DETECTOR
FLUORESCENT LEAK DETECTOR
InspectionINFOID:0000000003795981
CHECKING SYSTEM FOR LEAKAGES USING THE FLUORESCENT LEAK DETECTOR
1. Check A/C system for leakages using the UV lamp and safety goggles (SST: J-42220) in a low sunlight
area (area without windows preferable). Illuminate all components, fittings and lines. The dye appears as
a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open-
ing indicates an evaporator core assembly (tubes, core or expansion valve) leakage.
2. Use an adjustable mirror or wipe the area with a clean shop rag or cloth, with the UV lamp for dye residue
if the suspected area is difficult to see.
3. Remove any residual dye using dye cleaner (SST: J-43872) to prevent future misdiagnosis after the leak-
age is repaired.
4. Perform a system performance check and verify the leakage repair with an approved electrical leak detec-
tor.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This may also cause false readings
and may damage the detector.
DYE INJECTION
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2, 50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (SST: J-41459).
3. Connect the injector tool to the A/C low-pressure side service valve.
4. Start the engine. Then switch A/C ON.
5. Inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye through the low-pressure service valve using dye
injector tool (SST: J-41459) (refer to the manufacture’s operating instructions) when the A/C operating
(compressor running).
6. Disconnect the injector tool from the service valve with the engine still running.
CAUTION:
Be careful when replacing the A/C system or a component, pour the dye directly into the open sys-
tem connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leakage size, operating conditions and location of the leakage, it may take from minutes to days for the
dye to penetrate a leakage and become visible.
8. Attach a blue label if necessary.
INL-14
< FUNCTION DIAGNOSIS >
DIAGNOSIS SYSTEM (BCM)
DIAGNOSIS SYSTEM (BCM)
COMMON ITEM
COMMON ITEM : CONSULT-III Function (BCM - COMMON ITEM)INFOID:0000000003894737
APPLICATION ITEM
CONSULT-III performs the following functions via CAN communication with BCM.
SYSTEM APPLICATION
BCM can perform the following functions for each system.
NOTE:
It can perform the diagnosis modes except the following for all sub system selection items.
×: Applicable item
NOTE:
*: This item is displayed, but is not used.
FREEZE FRAME DATA (FFD) AND IGN COUNTER
Freeze Frame Data
Diagnosis mode Function Description
Work Support Changes the setting for each system function.
Self Diagnostic Result Displays the diagnosis results judged by BCM.
CAN Diag Support MonitorMonitors the reception status of CAN communication viewed from BCM. Refer to CONSULT-III opera-
tion manual.
Data Monitor The BCM input/output signals are displayed.
Active Test The signals used to activate each device are forcibly supplied from BCM.
Ecu Identification The BCM part number is displayed.
Configuration Read and save the vehicle specification.
Write the vehicle specification when replacing BCM.
System Sub system selection itemDiagnosis mode
Work Support Data Monitor Active Test
Door lock DOOR LOCK×××
Rear window defogger REAR DEFOGGER××
Warning chime BUZZER××
Interior room lamp timer INT LAMP×××
Exterior lamp HEAD LAMP×××
Wiper and washer WIPER×××
Turn signal and hazard warning lamps FLASHER×××
— AIR CONDITONER*
Intelligent Key system
Engine start systemINTELLIGENT KEY×××
Combination switch COMB SW×
Body control system BCM×
NVIS - NATS IMMU××
Interior room lamp battery saver BATTERY SAVER×××
Trunk lid opener system TRUNK××
Vehicle security system THEFT ALM×××
— RETAINED PWR*×
Signal buffer system SIGNAL BUFFER××
— TPMS (AIR PRESSURE MONITOR)*×××
BCM (BODY CONTROL MODULE)
INL-53
< ECU DIAGNOSIS >
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ECU DIAGNOSIS
BCM (BODY CONTROL MODULE)
Reference ValueINFOID:0000000003959702
VALUES ON THE DIAGNOSIS TOOL
CONSULT-III MONITOR ITEM
Monitor Item Condition Value/Status
FR WIPER HIOther than front wiper switch HI Off
Front wiper switch HI On
FR WIPER LOWOther than front wiper switch LO Off
Front wiper switch LO On
FR WASHER SWFront washer switch OFF Off
Front washer switch ON On
FR WIPER INTOther than front wiper switch INT Off
Front wiper switch INT On
FR WIPER STOPFront wiper is not in STOP position Off
Front wiper is in STOP position On
INT VOLUME Wiper intermittent dial is in a dial position 1 - 7 Wiper intermittent dial position
TURN SIGNAL ROther than turn signal switch RH Off
Turn signal switch RH On
TURN SIGNAL LOther than turn signal switch LH Off
Turn signal switch LH On
TAIL LAMP SWOther than lighting switch 1ST and 2ND Off
Lighting switch 1ST or 2ND On
HI BEAM SWOther than lighting switch HI Off
Lighting switch HI On
HEAD LAMP SW 1Other than lighting switch 2ND Off
Lighting switch 2ND On
HEAD LAMP SW 2Other than lighting switch 2ND Off
Lighting switch 2ND On
PA S S I N G S WOther than lighting switch PASS Off
Lighting switch PASS On
AUTO LIGHT SWOther than lighting switch AUTO Off
Lighting switch AUTO On
FR FOG SWFront fog lamp switch OFF Off
Front fog lamp switch ON On
RR FOG SWRear fog lamp switch OFF Off
Rear fog lamp switch ON On
DOOR SW-DRDriver door closed Off
Driver door opened On
DOOR SW-ASPassenger door closed Off
Passenger door opened On
DOOR SW-RRRear RH door closed Off
Rear RH door opened On
BCM (BODY CONTROL MODULE)
INL-69
< ECU DIAGNOSIS >
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107
(R/W)GroundCombination switch
INPUT 1InputCombination
switch
(Wiper intermit-
tent dial 4)All switch OFF
1.4 V
Turn signal switch LH
1.3 V
Turn signal switch RH
1.3 V
Front wiper switch LO
1.3 V
Front washer switch ON
1.3 V Te r m i n a l N o .
(Wire color)Description
ConditionVa l u e
(Approx.)
Signal nameInput/
Output +–
JPMIA0041GB
JPMIA0037GB
JPMIA0036GB
JPMIA0038GB
JPMIA0039GB