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CONTENTS
BODY, LOCK & SECURITY SYSTEM
SERVICE INFORMATION .. ..........................4
PRECAUTIONS .............................................. .....4
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
4
Precaution Necessary fo r Steering Wheel Rota-
tion After Battery Disconnect ............................... ......
4
Precaution for Procedure without Cowl Top Cover ......5
Precaution for Work ............................................ ......5
PREPARATION .............................................. .....6
Special Service Tool ........................................... ......6
Commercial Service Tool .................................... ......6
SQUEAK AND RATTLE TROUBLE DIAG-
NOSES ........................ ........................................7
Work Flow ........................................................... ......7
Generic Squeak and Rattle Troubleshooting ...... ......9
Diagnostic Worksheet ......................................... ....11
HOOD ............................................................. ....13
Fitting Adjustment ............................................... ....13
Removal and Installation .........................................14
Removal and Installation of Hood Lock Control .. ....15
Hood Lock Control Inspec tion .................................17
RADIATOR CORE SUPPORT ....................... ....19
Removal and Installation .........................................19
FRONT FENDER ............................................ ....21
Removal and Installation .........................................21
POWER DOOR LOCK SYSTEM .................... ....22
Component Parts and Harness Connector Loca-
tion ...................................................................... ....
22
System Description ............................................. ....23
CAN Communication System Description ........... ....25
Schematic ........................................................... ....26
Wiring Diagram - D/LOCK - ................................. ....27
Schematic ........................................................... ....31
Wiring Diagram - D/LOCK - ................................. ....32 Terminal and Reference
Value for BCM ..................37
Work Flow ............................................................ ....41
CONSULT-III Function (B CM) .................................41
Trouble Diagnosis Symptom Chart ...................... ....43
BCM Power Supply and Ground Circuit Inspection ....43
Door Switch Check (Hatchback) .......................... ....44
Door Switch Check (Sedan) ................................ ....47
Key Switch (Insert) Check ................................... ....48
Door Lock and Unlock Switch Check .................. ....49
Front Door Lock Assembly LH (Actuator) Check .....52
Door Lock Actuator Check (Front RH and Rear
LH/RH) ................................................................. ....
53
Front Door Key Cylinder S witch LH Check ..............54
Passenger Select Unlock Relay Circuit Inspection
(With Intelligent Key) ........................................... ....
55
REMOTE KEYLESS ENTRY SYSTEM ............. 58
Component Parts and Harness Connector Loca-
tion ....................................................................... ....
58
System Description .............................................. ....58
CAN Communication System Description ........... ....60
Schematic ............................................................ ....61
Wiring Diagram - KEYLES - ................................ ....62
Terminal and Reference Value for BCM ..................65
How to Perform Trouble Diagnosis ...................... ....69
Preliminary Check ............................................... ....69
CONSULT-III Function (B CM) .................................69
Work Flow ............................................................ ....71
Trouble Diagnosis Symptom Chart ...................... ....71
Keyfob Battery and Function Check .................... ....72
ACC Switch Check .............................................. ....74
Door Switch Check (Hatchback) .......................... ....74
Door Switch Check (Sedan) ................................ ....76
Key Switch (Insert) Check ................................... ....78
Hazard Function Check ....................................... ....78
Horn Function Check ........................................... ....79
Interior Lamp and Ignition Keyhole Illumination
Function Check .................................................... ....
79
Remote Keyless Entry Rece iver Check ...................80
Keyfob Function (Lock) Check ............................ ....82
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CONTENTS
BRAKE SYSTEM
SERVICE INFORMATION .. ..........................2
PRECAUTIONS .............................................. .....2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
2
Precaution Necessary fo r Steering Wheel Rota-
tion After Battery Disconnect ............................... ......
2
Precaution for Brake System .............................. ......3
PREPARATION .............................................. .....4
Special Service Tool ........................................... ......4
Commercial Service Tool .................................... ......4
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ........................ .....5
NVH Troubleshooting Chart ................................ ......5
BRAKE PEDAL .............................................. .....6
Inspection and Adjustment .................................. ......6
Removal and Installation ...........................................7
BRAKE FLUID .....................................................9
On Board Inspection ........................................... ......9
Drain and Refill .................................................... ......9
Bleeding Brake System ....................................... ......9
BRAKE TUBE AND HOSE ............................ ....11
Hydraulic Circuit .................................................. ....11
Front Brake Tube and Hose ................................ ....12
Rear Brake Tube and Hose ................................ ....12
Inspection After Installation ................................. ....13
DUAL PROPORTIONING VALVE ................. ....14
Removal and Installation .........................................14
Inspection ............................................................ ....14
BRAKE MASTER CY LINDER ........................ ....15
On-Board Inspection ........................................... ....15 Removal and Installation .....................................
....15
Disassembly and Assembly ................................. ....16
BRAKE BOOSTER ........................................... 20
On Board Inspection ............................................ ....20
Removal and Installation ..................................... ....21
VACUUM LINES ............................................... 23
Component .......................................................... ....23
Removal and Installation ..................................... ....23
Inspection ............................................................ ....23
FRONT DISC BRAKE ....................................... 25
On Board Inspection ............................................ ....25
Component .......................................................... ....25
Removal and Installation of Brake Pad ...................26
Removal and Installation of Brake Caliper Assem-
bly ........................................................................ ....
28
Disassembly and Assembly of Brake Caliper As-
sembly ................................................................. ....
29
Brake Burnishing Procedure ................................ ....32
REAR DRUM B RAKE ....................................... 33
Component .......................................................... ....33
Removal and Installation of Drum Brake Assembly ....34
Removal and Installation of Wheel Cylinder ........ ....37
Disassembly and Assembly of Wheel Cylinder ... ....37
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 38
General Specification .......................................... ....38
Brake Pedal ......................................................... ....39
Check Valve ........................................................ ....39
Brake Booster ...................................................... ....40
Front Disc Brake .................................................. ....40
Rear Drum Brake ................................................. ....40
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CONTENTS
CLUTCH
SERVICE INFORMATION .. ..........................2
PRECAUTIONS .............................................. .....2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
2
Precaution for Procedure without Cowl Top Cover ......2
Service Notice or Precaution ............................... ......2
PREPARATION .............................................. .....3
Special Service Tool ........................................... ......3
Commercial Service Tool .................................... ......3
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ........................ .....4
NVH Troubleshooting Chart ................................ ......4
CLUTCH PEDAL ............................................ .....5
On-vehicle Inspection and Adjustment ................ ......5
Removal and Installation ...........................................6
CLUTCH FLUID .............................................. .....8 Air Bleeding Procedure ........................................
.....8
CLUTCH MASTER CYLINDER ........................ 10
Removal and Installation ..................................... ....10
CSC (CONCENTRIC SLAVE CYLINDER) ....... 12
Exploded View ..................................................... ....12
Removal and Installation ..................................... ....12
CLUTCH PIPING ............................................... 14
Removal and Installation ..................................... ....14
CLUTCH DISC, CLUTCH COVER AND FLY-
WHEEL .............................................................. 15
Removal and Installation ..................................... ....15
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 18
Clutch Control System ......................................... ....18
Clutch Pedal ........................................................ ....18
Clutch Disc .......................................................... ....18
Clutch Cover ........................................................ ....18
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DATA MONITOR
Display Item List
ACTIVE TEST
Display Item List
SELF-DIAG RESULTS
Display Item List
NOTE:
If “CAN communication [U1000]” is indicated, after prin ting the monitor item, go to “LAN system”. Refer to
LAN-17, " Trouble Diagnosis Flow Chart " .
Trouble Diagnosis INFOID:0000000004307032
HOW TO PERFORM TROUBLE DIAGNOSIS 1. Confirm the symptom and customer complaint.
2. Understand the outline of system. Refer to DI-42, " System Description " .
3. Perform the preliminary inspection. Refer to "PRELIMINARY INSPECTION".
4. According to symptom c hart, repair or replace the cause of the malfunction. Refer to "SYMPTOM
CHART".
5. Does warning chime system operate normally? If it operates normally, GO TO 6. If not, GO TO 4.
6. Inspection End.
PRELIMINARY INSPECTION BCM diagnostic
test item Diagnostic mode Description
Inspection by part WORK SUPPORT
Supports inspections and adjustments. Commands are transmitted to the BCM for
setting the status suitable for required operation, input/output signals are received
from the BCM and received data is displayed.
DATA MONITOR Displays BCM input/output data in real time. ACTIVE TEST Operation of electrical loads can be checked by sending drive signal to them.
SELF-DIAG RESULTS Displays BCM self-diagnosis results.
CAN DIAG SUPPORT MNTR The result of transmit/receive diagnosis of CAN communication can be read. ECU PART NUMBER BCM part number can be read.CONFIGURATION Performs BCM configuration read/write functions. Monitored item ALL SIGNALS
SELECTION
FROM MENU Contents
IGN ON SW X X Indicates [ON/OFF] condition of ignition switch.
KEY ON SW X X Indicates [ON/OFF] condition of key switch.
DOOR SW-DR X X Indicates [ON/OFF] condition of front door switch LH.
LIGHT SW 1ST X X Indicates [ON/OFF] condition of lighting switch.
BUCKLE SW X X Indicates [ON/OFF] condition of seat belt buckle switch LH. Test item Malfunction is detected when···
IGN KEY WARN ALM This test is able to check key warning chime operation.
LIGHT WARN ALM This test is able to check light warning chime operation.
SEAT BELT WARN TEST This test is able to check seat belt warning chime operation. Display item [Code] Malfunction is detected when...
CAN communication [U1000] Malfunction is detected in CAN communication.
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3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, se curing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun visor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
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.
OVERHEAD CONSOLE (FRONT AND REAR) Overhead console noises are often caused by the cons ole panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the c onsole at the clip locations until the clips engage.
In addition look for:
1. Loose harness or harness connectors.
2. Front console map/reading lamp lens loose.
3. Loose screws at console attachment points.
SEATS When isolating seat noise it's important to note the pos ition the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplic ated 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. The 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 thes e 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 installed on the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator 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 c an usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
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CONTENTS
ENGINE MECHANICAL
HR16DE
PRECAUTION ....... ........................................
4
PRECAUTIONS .............................................. .....4
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
4
Precaution Necessary fo r Steering Wheel Rota-
tion After Battery Disconnect ............................... ......
4
Precaution for Procedure without Cowl Top Cover ......5
Precaution for Drain Cool ant .....................................5
Precaution for Disconnecting Fuel Piping ........... ......5
Precaution for Removal and Disassembly ................5
Precaution for Inspection, Repair and Replace-
ment .................................................................... ......
5
Precaution for Assembly and Installation ..................5
Parts Requiring Angular Tightening ..........................6
Precaution for Liquid Gasket ............................... ......6
PREPARATION .... ........................................8
PREPARATION .............................................. .....8
Special Service Tools .......................................... ......8
Commercial Service Tools .................................. ......9
SYMPTOM DIAGNOSIS ..... .........................12
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ........................ ....
12
NVH Troubleshooting - Engine Noise ................. ....12
Use the Chart Below to Help You Find the Cause
of the Symptom ................................................... ....
13
ON-VEHICLE MAINTENA NCE ....................14
DRIVE BELTS ................................................ ....14
Checking ............................................................. ....14
Tension Adjustment ............................................ ....14
Removal and Installation .........................................15
AIR CLEANER FILTER .................................. ....17 Removal and Installation .....................................
....17
SPARK PLUG ................................................... 18
Exploded View ..................................................... ....18
Removal and Installation ..................................... ....18
CAMSHAFT VALVE CLEARANCE .................. 20
Inspection and Adjustment .................................. ....20
COMPRESSION PRESSURE ........................... 23
Inspection ............................................................ ....23
ON-VEHICLE REPAIR ..... ............................24
DRIVE BELT IDLER PULLEY .......................... 24
Exploded View ..................................................... ....24
Removal and Installation ..................................... ....24
AIR CLEANER AND AIR DUCT ....................... 26
Exploded View ..................................................... ....26
Removal and Installation ..................................... ....26
Inspection ............................................................ ....27
INTAKE MANIFOLD ......................................... 28
Exploded View ..................................................... ....28
Removal and Installation ..................................... ....28
EXHAUST MANIFOLD ...................................... 31
Exploded View ..................................................... ....31
Removal and Installation ..................................... ....31
FUEL INJECTOR AND FUEL TUBE ................ 34
Exploded View ..................................................... ....34
Removal and Installation ..................................... ....34
Inspection ............................................................ ....38
OIL PAN (LOWER) ........................................... 39
Exploded View ..................................................... ....39
Removal and Installation ..................................... ....39
Inspection ............................................................ ....41
OIL PAN (UPPER) AND OIL STRAINER ......... 42
Component .......................................................... ....42
EM-70< ON-VEHICLE REPAIR >
[HR16DE]
CAMSHAFT
c. Tighten bolts in the numerical order shown.
d. After all bolts are tightened, retighten them to specified torque in numerical order as shown.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface.
22. Insert crankshaft pulley by aligning with crankshaft key. • When inserting crankshaft pulley with a plastic hamme r, tap on its center portion (not circumference).
CAUTION:
Never damage front oil seal lip section.
23. Tighten crankshaft pulley bolt with the following procedure: • Secure crankshaft pulley with a suitable tool, and tighten crankshaft pulley bolt.
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt.
c. Put a paint mark (B) on crankshaft pulley, mating with any one of six easy to recognize angle marks (A) on crankshaft bolt flange
(1).
d. Turn another 60 degrees clockwise (angle tightening). • Check the tightening angle with movement of one angle mark.
24. Make sure that crankshaft turns smoothly by rotating by hand clockwise.
25. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.
• Tighten bolts with it seated completely.
26. Check and adjust valve clearance. Refer to EM-20, " Inspection and Adjustment " .
27. Installation of the remaining components is in the reverse order of removal.
Inspection INFOID:0000000004784301
INSPECTION AFTER REMOVAL
Oil Filter KBIA3429J
Crankshaft pulley bolt : 35.0 N·m (3.6 kg-m, 26 ft-lb)
PBIC3726E
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Most of these incidents can be repaired by adjusting, se
curing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun visor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
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.
OVERHEAD CONSOLE (FRONT AND REAR) Overhead console noises are often caused by the cons ole panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the c onsole at the clip locations until the clips engage.
In addition look for:
1. Loose harness or harness connectors.
2. Front console map/reading lamp lense loose.
3. Loose screws at console attachment points.
SEATS When isolating seat noise it's important to note the pos ition the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplic ated 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. The 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 thes e 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 c an usually be made by moving, adjusting, securing, or
insulating the component causing the noise.