Aveo
BODY REPAIR MANUAL
0. SERVICE NOTICE
HOW TO USE THIS MANUAL
SPECIAL INFORMATION
SRS
1. GENERAL INFORMATION
GENERAL INSTRUCTION
IMPORTANT SAFETY NOTICE
BEFORE BEGINNING WORK
DURING WORK
BODY SAFETY
LOADS ON BODY PARTS
USE OF NEW HIGH-QUALITY MATERIALS
CORROSION PROTECTION
SUMMARY
ZINC TREATED STEEL PLATE REPAIR
TECHNICAL ILLUSTRATION
BODY REPAIR PROCEDURES
2. PREPARATIONS OF BODYWORK
GENERAL DESCRIPTION
CHECKPOINTS
CORRECTION OF THE DAMAGED AREA
WITHOUT SMALL DAMAGE
3. WELDING AND TOOLS
SPOT WELDING
GENERAL DESCRIPTION
WELDING CONDITIONS
WELDING STRENGTH TEST
GAS WELDING
MIG ARC WELDING
REPAIR TOOLS
4. FRONT
FRONT PANEL
GENERAL DESCRIPTION
REPAIR PROCEDURE
FRONT WHEELHOUSE
GENERAL DESCRIPTION
REPAIR PROCEDURE
FRONT LONGITUDINAL
GENERAL DESCRIPTION
REPAIR PROCEDURE
SUPPORT CONTROL ARM
GENERAL DESCRIPTION
REPAIR PROCEDURE
FRONT PILLAR
GENERAL DESCRIPTION
REPAIR PROCEDURE
5. ROOF, BACK PANEL AND REAR FLOOR PANEL
ROOF
GENERAL DESCRIPTION
REPAIR PROCEDURE
BACK PANEL
GENERAL DESCRIPTION
REPAIR PROCEDURE
REAR FLOOR PANEL
GENERAL DESCRIPTION
REPAIR PROCEDURE
6. FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER
FRAME DOOR OPENING
GENERAL DESCRIPTION
REPAIR PROCEDURE
DOOR
REPAIR PROCEDURE
SIDE PANEL OUTER
GENERAL DESCRIPTION
REPAIR PROCEDURE
7. FENDER, HOOD, TAILGATE AND TRUNK LID
FENDER
REPAIR PROCEDURE
HOOD
REPAIR PROCEDURE
TRUNK LID
REPAIR PROCEDURE
8. BODY DIMENSION
BODY DRAWING
UNDER BODY
FRONT PANEL
ENGINE ROOM
BACK PANEL LOWER
SIDE OUTER
REPAIR DRAWING
FRAME DOOR OPENING
WINDSHIELD AND REAR GLASS
LUGGAGE COMPARTMENT
GAP CHART
9. SEALING, CAULKING AND DEADNER
SEALING & CAULKING
DEADNER
GENERAL DESCRIPTION
REPAIR PROCEDURE
10. RUST PREVENTION
ZINC TREATED STEEL PLATE REPAIR
RUST PREVENTIVE PROCEDURE
GENERAL INFORMATION
AREA COVERED BY ANTI-RUST AGENTS
UNDERCOATING DIAGRAM
ELECTRICAL WIRING DIAGRAMS
LHD
1. HOW TO READ ELECTRICAL WIRING DIAGRAM
1. HOW TO READ ELECTRIC WIRING DIAGRAM
1) CONTENTS OF ELECTRICAL WIRING DIAGRAM (CIRCUIT)
2. CIRCUIT IDENTIFICATION SYMBOL
3. FUNCTION OF POWER SUPPLY LINE (NUMBER)
4. WIRING HARNESS COLOR IDENTIFICATION
5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR
2. POSITION OF CONNECTORS AND GROUNDS
1. CONNECTOR, GROUND AND SPLICE PACK INFORMATION
1) WIRING HARNESS & GROUND & SPLICE PACK LOCATION
2) CONNECTOR INFORMATION
3) GROUND POSITION INFORMATION
4) SPLICE PACK INFORMATION
2. WIRING HARNESS, CONNECTOR & GROUND LOCATION
1) W/H FRONT
2) W/H INSTRUMENT PANEL
3) W/H ENGINE CONTROL & BATTERY
4) W/H FLOOR
5) W/H TCM
6) W/H DOOR
7) W/H TAILGATE
8) W/H ROOF
9) W/H AIRBAG
10) W/H TRUNK
11) W/H REAR
12) SPLICE PACK
3. WIRING DIAGRAM FOR POWER SUPPLIES
1. IGNITION SWITCH CIRCUIT
2. CONTROLLER CIRCUIT (I/P FUSE BLOCK)
3. 15 TER "IGN1", 15C "ACC", 15A "IGN2" POWER SUPPLY CIRCUIT (I/P FUSE BLOCK)
4. ENGINE FUSE BLOCK & RELAY CIRCUIT
4. USAGE AND CAPACITY OF FUSES IN FUSE BLOCK
1. ENGINE ROOM RELAY AND FUSE BLOCK
1) POSITION OF RELAY AND FUSE
2) USAGE OF FUSE IN ENGINE FUSE BLOCK
2. I/P FUSE BLOCK
1) POSITION OF RELAY AND FUSE
2) USAGE OF FUSE IN I/P FUSE BLOCK
5. ELECTRICAL WIRING DIAGRAMS
1. STARTING & CHARGING SYSTEM
1) BATTERY, IGNITION SWITCH, STARTER MOTOR, GENERATOR & PNP SWITCH CIRCUIT
2. ECM (ENGINE CONTROL MODULE) : MR : 140
1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM, CKP SENSOR & CMP SENSOR CIRCUIT
2) FUEL PUMP, INJECTOR & O2 SENSOR CIRCUIT : EXCEPT EURO IV
3) FUEL PUMP, INJECTOR & O2 SENSOR CIRCUIT : EURO IV
4) IAC, SENSOR (MAP, ECT, TP, KNOCK, ACP), LEGR & ROUGH ROAD CIRCUIT
5) EVAP CANISTER PURGE SOLENOID, CLUSTER & VSS CIRCUIT
6) CLUSTER, FUEL PUMP & TCM CIRCUIT
7) DLC, MIL & RON SWITCH CIRCUIT
3. ECM (ENGINE CONTROL MODULE) : HV : 240
1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM, CKP SENSOR & CMP SENSOR CIRCUIT
2) FUEL PUMP, INJECTOR & O2 SENSOR CIRCUIT
3) IAC & SENSOR (MAP, ECT, TP, IAT, KNOCK, ACP) CIRCUIT
4) EVAP CANISTER PURGE SOLENOID, CLUSTER & VSS CIRCUIT
5) CLUSTER, FUEL PUMP & TCM CIRCUIT
6) DLC, MIL & RON SWITCH CIRCUIT
4. ECM (ENGINE CONTROL MODULE) : SIRIUS D42R
1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM & CKP SENSOR CIRCUIT
2) FUEL PUMP, INJECTOR & O2 SENSOR CIRCUIT
3) IAC & SENSOR (ECT, ROUGH ROAD, T-MAP, ACP, EVAPORATOR TEMPERATURE & KNOCK) CIRCUIT
4) CLUSTER, EEGR VALVE, FUEL PUMP & TCM CIRCUIT
5) CMP SENSOR, EVAP CANISTER PURGE SOLENOID, CLUSTER & VSS CIRCUIT
6) CLUSTER, POWER STEERING PRESSURE SWITCH & RON SWITCH CIRCUIT
7) DLC, MIL & RON SWITCH CIRCUIT
5. ECM (ENGINE CONTROL MODULE) : MT80
1) BATTERY POWER SUPPLY, GROUND, IGNITION COIL, CKP SENSOR & CMP SENSOR CIRCUIT
2) FUEL PUMP, INJECTOR, ECT SENSOR2 & O2 SENSOR CIRCUIT
3) ETC, SENSOR (MAP, ECT, KNOCK, ACP, ROUGH ROAD) & THERMOSTAT HEATER CIRCUIT
4) EVAP CANISTER PURGE SOLENOID, EVAP EMISSION VENT. SOLENOID, CLUSTER & VSS CIRCUIT
5) CLUSTER, FUEL PUMP, TNAK PRESSURE SENSOR, CMP ACTUATOR & TCM CIRCUIT
6) DLC, MIL CIRCUIT
7) CLUSTER, ACCEL PEDAL SENSOR, BRAKE SWITCH & RON SWITCH CIRCUIT
6. TCM (TRANSMISSION CONTROL MODULE)
1) POWER SUPPLY, GROUND, PNP SWITCH & ECM CIRCUIT
2) SOLENOID, STOP LAMP SWITCH, OIL TEMPERATURE SENSOR & INPUT SHIFT SPEED SENSOR (ISS) CIRCUIT
3) VSS & HOLD SWITCH CIRCUIT
7. AIR CONDITIONER
1) BLOWER MOTOR CONTROL CIRCUIT
2) A/C COMPRESSOR CONTROL CIRCUIT : SIRIUS D42
3) A/C COMPRESSOR CONTROL CIRCUIT : HV-240
4) A/C COMPRESSOR CONTROL CIRCUIT : MR-140
5) A/C COMPRESSOR CONTROL CIRCUIT : MT80
6) POWER, GROUND AND INTAKE ACTUATOR CIRCUIT
8. FATC (FULL AUTOMATIC TEMPERATURE CONTROL CIRCUIT)
1) POWER, GROUND & SENSOR CIRUCIT
2) A/C COMPRESSOR CONTROL CIRCUIT : SIRIUS D42
3) A/C COMPRESSOR CONTROL CIRCUIT : HV-240
4) A/C COMPRESSOR CONTROL CIRCUIT : MR-140
5) A/C COMPRESSOR CONTROL CIRCUIT : MT80
6) BLOWER AND AIR DELIVERY CIRCUIT
9. RADIATOR COOLING FAN CIRCUIT
1) COOLING FAN CIRCUIT : SIRIUS D42R
2) COOLING FAN CIRCUIT : HV-240
3) COOLING FAN CIRCUIT : MR-140
4) COOLING FAN CIRCUIT : MT80
10. HEAD LAMP & HEAD LAMP LEVELING DEVICE (HLLD) CIRCUIT
11. DRL (DAY TIME RUNNING LIGHT) CIRCUIT
12. ILLUMINATION CIRCUIT
1) ILLUMINATION CIRCUIT-W/O DIMMER CONTROL
2) ILLUMINATION CIRCUIT-W/ DIMMER CONTROL
3) LAMP (LICENSE PLATE & W/ FRONT/REAR PARKING) CIRCUIT : HATCH BACK
4) LAMP (LICENSE PLATE & W/ FRONT/REAR PARKING) CIRCUIT : NOTCH BACK
13. FRONT & REAR FOG LAMP CIRCUIT
1) FOG LAMP CIRCUIT : HATCH BACK
2) FOG LAMP CIRCUIT : NOTCH BACK
14. HAZARD & TURN SIGNAL LAMP CIRCUIT
1) HATCH BACK
2) NOTCH BACK
15. STOP LAMP, CENTER HIGH MOUNT STOP LAMP (CHMSL) & REVERSE LAMP CIRCUIT
16. HORN, POWER JACK, ASHTRAY LAMP & CIGAR LIGHTER CIRCUIT
17. LAMPS (ROOM, DOOR OPENING WARNING) CIRCUIT
18. CHIME BELL, SEAT BELT & KEY REMIND SWITCH CIRCUIT
19. WIPER CIRCUIT
1) WIPER CIRCUIT : FRONT WIPER
2) WIPER CIRCUIT : FRONT WIPER (W/O INT)
3) WIPER CIRCUIT : REAR WIPER (W/ INT)
20. REAR WINDOW DEFROSTER & OSRV MIRROR HEATING SYSTEM CIRCUIT
21. ELECTRIC OSRV MIRROR CIRCUIT
22. POWER WINDOW CIRCUIT
1) ONLY FRONT POWER WINDOW CIRCUIT
2) FRONT & REAR POWER WINDOW CIRCUIT
3) SAFETY POWER WINDOW CIRCUIT
23. CENTRAL DOOR LOCKING SYSTEM CIRCUIT
24. CLUSTER
1) TACHOMETER, FUEL GAUGE & COOLANT TEMPERATURE GAUGE : SIRIUS D42R
2) TACHOMETER, FUEL GAUGE & COOLANT TEMPERATURE GAUGE : MR140
3) TACHOMETER, FUEL GAUGE & COOLANT TEMPERATURE GAUGE : HV240
4) TACHOMETER, FUEL GAUGE & COOLANT TEMPERATURE GAUGE : MT80
5) SPEEDOMETER & AMBIENT TEMPERATURE INDICATOR
6) WARNING INDICATORS
7) WARNING INDICATORS
8) INDICATOR LAMP & ILLUMINATON
25. CLOCK
26. AUDIO CIRCUIT
27. ANTI LOCK BRAKE SYSTEM (ABS)
1) POWER SUPPLY, WHEEL SPEED SENSOR & OIL FEEDING CONNECTOR CIRCUIT
2) PARKING BRAKE, BRAKE FLUID SWITCH & WARNING(ABS,BRAKE)LAMP CIRCUIT
28. AIR BAG (SDM : SENSING & DIAGNOSTIC MODULE)
29. SUN ROOF CIRCUIT
30. IMMOBILIZER SYSTEM CIRCUIT
31. ANTI-THEFT CONTROL SYSTEM CIRCUIT
1) HATCH BACK
2) NOTCH BACK
32. BATTERY SAVER CIRCUIT
RHD
1. HOW TO READ ELECTRICAL WIRING DIAGRAM
1. HOW TO READ ELECTRIC WIRING DIAGRAM
1) CONTENTS OF ELECTRICAL WIRING DIAGRAM (CIRCUIT)
2. CIRCUIT IDENTIFICATION SYMBOL
3. FUNCTION OF POWER SUPPLY LINE (NUMBER)
4. WIRING HARNESS COLOR IDENTIFICATION
5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR
2. POSITION OF CONNECTORS AND GROUNDS
1. CONNECTOR, GROUND AND SPLICE PACK INFORMATION
1) WIRING HARNESS & GROUND & SPLICE PACK LOCATION
2) CONNECTOR INFORMATION
3) GROUND POSITION INFORMATION
4) SPLICE PACK INFORMATION
2. WIRING HARNESS, CONNECTOR & GROUND LOCATION
1) W/H FRONT
2) W/H INSTRUMENT PANEL
3) W/H ENGINE CONTROL & BATTERY
4) W/H FLOOR
5) W/H TCM
6) W/H DOOR
7) W/H TAILGATE
8) W/H ROOF
9) W/H AIRBAG
10) W/H TRUNK
11) W/H REAR
12) SPLICE PACK
3. WIRING DIAGRAM FOR POWER SUPPLIES
1. IGNITION SWITCH CIRCUIT
2. CONTROLLER CIRCUIT (I/P FUSE BLOCK)
3. 15 TER "IGN1", 15C "ACC", 15A "IGN2" POWER SUPPLY CIRCUIT (I/P FUSE BLOCK)
4. ENGINE FUSE BLOCK & RELAY CIRCUIT
4. USAGE AND CAPACITY OF FUSES IN FUSE BLOCK
1. ENGINE ROOM RELAY AND FUSE BLOCK
1) POSITION OF RELAY AND FUSE
2) USAGE OF FUSE IN ENGINE FUSE BLOCK
2. I/P FUSE BLOCK
1) POSITION OF RELAY AND FUSE
2) USAGE OF FUSE IN I/P FUSE BLOCK
5. ELECTRICAL WIRING DIAGRAMS
1. STARTING & CHARGING SYSTEM
1) BATTERY, IGNITION SWITCH, STARTER MOTOR, GENERATOR & PNP SWITCH CIRCUIT
2. ECM (ENGINE CONTROL MODULE) : MR : 140
1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM, CKP SENSOR & CMP SENSOR CIRCUIT
2) FUEL PUMP, INJECTOR & O2 SENSOR CIRCUIT : EXCEPT EURO IV
3) FUEL PUMP, INJECTOR & O2 SENSOR CIRCUIT : EURO IV
4) IAC, SENSOR (MAP, ECT, TP, KNOCK, ACP), LEGR & ROUGH ROAD CIRCUIT
5) EVAP CANISTER PURGE SOLENOID, CLUSTER & VSS CIRCUIT
6) CLUSTER, FUEL PUMP & TCM CIRCUIT
7) DLC, MIL & RON SWITCH CIRCUIT
3. ECM (ENGINE CONTROL MODULE) : HV : 240
1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM, CKP SENSOR & CMP SENSOR CIRCUIT
2) FUEL PUMP, INJECTOR & O2 SENSOR CIRCUIT
3) IAC & SENSOR (MAP, ECT, TP, IAT, KNOCK, ACP) CIRCUIT
4) EVAP CANISTER PURGE SOLENOID, CLUSTER & VSS CIRCUIT
5) CLUSTER, FUEL PUMP & TCM CIRCUIT
6) DLC, MIL & RON SWITCH CIRCUIT
4. ECM (ENGINE CONTROL MODULE) : SIRIUS D42R
1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM & CKP SENSOR CIRCUIT
2) FUEL PUMP, INJECTOR & O2 SENSOR CIRCUIT
3) IAC & SENSOR (ECT, ROUGH ROAD, T-MAP, ACP, EVAPORATOR TEMPERATURE & KNOCK) CIRCUIT
4) CLUSTER, EEGR VALVE, FUEL PUMP CIRCUIT
5) CMP SENSOR, EVAP CANISTER PURGE SOLENOID, CLUSTER & VSS CIRCUIT
6) CLUSTER, POWER STEERING PRESSURE SWITCH & RON SWITCH CIRCUIT
7) DLC, MIL & RON SWITCH CIRCUIT
5. ECM (ENGINE CONTROL MODULE) : MT80
1) BATTERY POWER SUPPLY, GROUND, IGNITION COIL, CKP SENSOR & CMP SENSOR CIRCUIT
2) FUEL PUMP, INJECTOR, ECT SENSOR2 & O2 SENSOR CIRCUIT
3) ETC, SENSOR (MAP, ECT, KNOCK, ACP, ROUGH ROAD) & THERMOSTAT HEATER CIRCUIT
4) EVAP CANISTER PURGE SOLENOID, CLUSTER & VSS CIRCUIT
5) CLUSTER, FUEL PUMP, CMP ACTUATOR & TCM CIRCUIT
6) DLC, MIL CIRCUIT
7) CLUSTER, ACCEL PEDAL SENSOR, BRAKE SWITCH & RON SWITCH CIRCUIT
6. TCM (TRANSMISSION CONTROL MODULE)
1) POWER SUPPLY, GROUND, PNP SWITCH & ECM CIRCUIT
2) SOLENOID, STOP LAMP SWITCH, OIL TEMPERATURE SENSOR & INPUT SHIFT SPEED SENSOR (ISS) CIRCUIT
3) VSS & HOLD SWITCH CIRCUIT
7. AIR CONDITIONER
1) BLOWER MOTOR CONTROL CIRCUIT
2) A/C COMPRESSOR CONTROL CIRCUIT : SIRIUS D42R
3) A/C COMPRESSOR CONTROL CIRCUIT : HV-240
4) A/C COMPRESSOR CONTROL CIRCUIT : MR-140
5) A/C COMPRESSOR CONTROL CIRCUIT : MT80
6) POWER, GROUND AND INTAKE ACTUATOR CIRCUIT
8. FATC (FULL AUTOMATIC TEMPERATURE CONTROL CIRCUIT)
1) POWER, GROUND & SENSOR CIRUCIT
2) A/C COMPRESSOR CONTROL CIRCUIT : SIRIUS D42R
3) A/C COMPRESSOR CONTROL CIRCUIT : HV-240
4) A/C COMPRESSOR CONTROL CIRCUIT : MR-140
5) A/C COMPRESSOR CONTROL CIRCUIT : MT80
6) BLOWER AND AIR DELIVERY CIRCUIT
9. RADIATOR COOLING FAN CIRCUIT
1) COOLING FAN CIRCUIT : SIRIUS D42R
2) COOLING FAN CIRCUIT : HV-240
3) COOLING FAN CIRCUIT : MR-140
4) COOLING FAN CIRCUIT : MT80
10. HEAD LAMP & HEAD LAMP LEVELING DEVICE (HLLD) CIRCUIT
11. ILLUMINATION CIRCUIT
1) ILLUMINATION CIRCUIT-W/O DIMMER CONTROL
2) ILLUMINATION CIRCUIT-W/ DIMMER CONTROL
3) LAMP (LICENSE PLATE & W/ FRONT/REAR PARKING) CIRCUIT : HATCH BACK
4) LAMP (LICENSE PLATE & W/ FRONT/REAR PARKING) CIRCUIT : NOTCH BACK
12. FRONT & REAR FOG LAMP CIRCUIT
13. HAZARD & TURN SIGNAL LAMP CIRCUIT
14. STOP LAMP, CENTER HIGH MOUNT STOP LAMP (CHMSL) & REVERSE LAMP CIRCUIT
15. HORN, POWER JACK, ASHTRAY LAMP & CIGAR LIGHTER CIRCUIT
16. LAMPS (ROOM, DOOR OPENING WARNING) CIRCUIT
17. CHIME BELL, SEAT BELT & KEY REMIND SWITCH CIRCUIT
18. WIPER CIRCUIT
1) WIPER CIRCUIT : FRONT WIPER
2) WIPER CIRCUIT : REAR WIPER (W/O INT)
3) WIPER CIRCUIT : REAR WIPER (W/ INT)
19. REAR WINDOW DEFROSTER & OSRV MIRROR HEATING SYSTEM CIRCUIT
20. ELECTRIC OSRV MIRROR CIRCUIT
21. POWER WINDOW CIRCUIT
1) ONLY FRONT POWER WINDOW CIRCUIT
2) FRONT & REAR POWER WINDOW CIRCUIT
3) SAFETY POWER WINDOW CIRCUIT
22. CENTRAL DOOR LOCKING SYSTEM CIRCUIT
23. CLUSTER
1) TACHOMETER, FUEL GAUGE & COOLANT TEMPERATURE GAUGE : SIRIUS D42
2) TACHOMETER, FUEL GAUGE & COOLANT TEMPERATURE GAUGE : MR140
3) TACHOMETER, FUEL GAUGE & COOLANT TEMPERATURE GAUGE : HV240
4) TACHOMETER, FUEL GAUGE & COOLANT TEMPERATURE GAUGE : MT80
5) SPEEDOMETER & AMBIENT TEMPERATURE INDICATOR
6) WARNING INDICATORS
7) WARNING INDICATORS
8) INDICATOR LAMP & ILLUMINATON
24. CLOCK
25. AUDIO CIRCUIT
26. ANTI LOCK BRAKE SYSTEM (ABS)
1) POWER SUPPLY, WHEEL SPEED SENSOR & OIL FEEDING CONNECTOR CIRCUIT
2) ABS DRIVER LAMP MODULE, PARKING BRAKE, BRAKE FLUID SWITCH & WARNING(ABS,BRAKE)LAMP CIRCUIT
27. AIR BAG (SDM : SENSING & DIAGNOSTIC MODULE)
28. SUN ROOF CIRCUIT
29. IMMOBILIZER SYSTEM CIRCUIT
30. ANTI-THEFT CONTROL SYSTEM CIRCUIT
1) HATCH BACK
2) NOTCH BACK
31. BATTERY SAVER CIRCUIT
LABOUR TIME GUIDE
0. General Information
1. INTRODUCTION
1-1. PAGE LAYOUT
1-2. TYPES OF OPERATION
Major Operation
Supplementary Operation (Adds)
1-3. TIME ALLOWANCES
2. HOW TO READ THIS MANUAL
Section
Illustration Number
Operation Description
3A. Major Operation
3B. Supplementary Operation
Operation Code
1) Main Group Code
2) Basic Code
3) Auxiliary Code
Major Operation
Supplementary Operation (ADD)
Operation Times
Model Code
Engine Type
3. HOW TO USE THIS MANUAL
4. PAINT REPAIR
4-1. INSTRUCTION
4-2. LABOR TIME
4-3. REPAIR TYPE
4-4. HOW TO USE OPERATION CODE FOR PARTIAL PAINTING
5. DEFECT CODE
5-1. NATURE CODES
5-2. CAUSE CODES
5-3. PAINT CODES
6. ABBREVIATIONS
7. MAIN GROUP CODE
1. Engine
MECHANICAL - SOHC GASOLINE
SOHC ENGINE UNIT (111)
BELT SYSTEM (113)
ENGINE BLOCK (121)
CRANK SHAFT & PISTON (122)
OIL PAN & PUMP (123)
CYLINDER HEAD (131)
CAM SUPPORT & SHAFT (132)
TIMING COVER (133)
ENGINE & TRANSAXLE MOUNT (138)
MECHANICAL - SOHC DIESEL
SOHC ENGINE UNIT (111)
BELT SYSTEM (113)
ENGINE BLOCK (121)
CRANKSHAFT & PISTON (122)
OIL PAN & PUMP (123)
CYLINDER HEAD (131)
CAM SUPPORT & SHAFT (132)
TIMING COVER (133)
ENGINE & TRANSAXLE MOUNT (138)
MECHANICAL - DOHC
DOHC ENGINE UNIT (111)
BELT SYSTEM (113)
ENGINE BLOCK (121)
CRANKSHAFT & PISTON (122)
OIL PAN & PUMP (123)
CYLINDER HEAD (131)
CAM SUPPORT & SHAFT (132)
TIMING COVER (133)
ENGINE & TRANSAXLE MOUNT (138)
COOLING - GASOLINE
RADIATOR (141)
COOLING FAN (143)
RADIATOR HOSE & PIPE (145)
THERMOSTAT (148)
COOLING - DIESEL
RADIATOR (141)
COOLING FAN (143)
RADIATOR HOSE & PIPE (145)
THERMOSTAT (148)
ELECTRICAL - GASOLINE
IGNITION CABLE (151)
ALTERNATOR UNIT (154)
STARTER (156)
BATTERY (157)
FUSE & RELAY (158)
ELECTRICAL - DIESEL
IGNITION CABLE (151)
ALTERNATOR UNIT (154)
STARTER (156)
BATTERY (157)
FUSE & RELAY (158)
CONTROLS - GASOLINE
FUEL TANK (171)
FUEL LINE (172)
CANISTER & FUEL VACUUM (173)
FUEL INJECTION (181)
ACCELERATOR CONTROL (182)
EMISSION CONTROL (186)
CONTROLS - DIESEL
FUEL TANK (171)
FUEL LINE (172)
CANISTER & FUEL VACUUM (173)
FUEL INJECTION (181)
ACCELERATOR CONTROL (182)
EMISSION CONTROL (186)
INTAKE & EXHAUST - GASOLINE
AIR INTAKE SYSTEM (191)
INTAKE MANIFOLD (193)
EXHAUST MANIFOLD (194)
VACUUM HOSE (195)
EXHAUST PIPE LINE (196)
INTAKE & EXHAUST - DIESEL
AIR INTAKE SYSTEM (191)
INTAKE MANIFOLD (193)
EXHAUST MANIFOLD (194)
VACUUM HOSE (195)
EXHAUST PIPE LINE (196)
2. Suspension
FRONT SUSPENSION
KNUCKLE & HUB (213)
FRONT SHOCK ABSORBER (214)
CONTROL ARM (215)
REAR SUSPENSION
REAR AXLE (231)
REAR SHOCK ABSORBER (232)
TIRES & WHEEL
WHEELS & WHEEL COVER (241)
TIRE PRESSURE MONITORING SYSTEM (242)
3. Driveline Axle
AXLE SHIFT PARTS (321)
4. Brakes
BRAKE PIPE (425)
BRAKE PEDAL & MOUNT (428)
MASTER CYLINDER & BOOSTER (431)
FRONT BRAKE (445)
REAR BRAKE (456)
ANTI-LOCK BRAKE SYSTEM (462)
PARKING BRAKE (478)
5. Transmissions/Transaxle
ZF 16HP AUTO TRANSAXLE
AUTOMATIC TRANSAXLE I (524)
AUTOMATIC TRANSAXLE II (525)
AUTOMATIC TRANSAXLE III (526)
AUTOMATIC TRANSAXLE IV(527)
AISIN AUTO TRANSAXLE : 81-40 / 80-40LE
AUTOMATIC TRANSAXLE (531)
CASE & RELATED PARTS (532)
INTERNAL POWERTRAIN PARTS (533)
GEAR ASSEMBLY (534)
CONTROL VALVE (535)
FLUID COOLER PIPE (536)
AUTOMATIC TRANSAXLE CONTROLS (537)
AISIN AUTO TRANSAXLE : 55-51LE
AUTOMATIC TRANSAXLE (531)
CASE & RELATED PARTS (532)
INTERNAL POWER TRAIN PARTS (533)
GEAR ASSEMBLY (534)
CONTROL VALVE (535)
FLUID COOLER PIPE (536)
AUTOMATIC TRANSAXLE CONTROLS (537)
GMPT AUTO TRANSAXLE : 6T40/45
CASE AND ASSOCIATED PARTS (541)
TRANSMISSION CASE ASSEMBLY (542)
DRIVE LINK ASSEMBLY (543)
CONTROL VALVE BODY ASSEMBLY (544)
LOW/REVERSE AND CLUTCH ASSEMBLY (545)
INPUT, OUTPUT AND REACTION GEARSETS (546)
PARK SYSTEM COMPONENTS (547)
AUTOMATIC TRANSAXLE CONTROLS (548)
AUTOMATIC TRANSAXLE CONTROLS (549)
FIVE-SPEED MANUAL TRANSAXLE: D16, D20
MANUAL TRANSAXLE (561)
TRANSAXLE GEAR (563)
REVERSE & COUNTER GEAR (564)
BEARING PLATE (565)
GEAR SHIFT COVER & FORK (566)
DIFFERENTIAL GEAR (567)
SHIFT CONTROL (569)
FIVE-SPEED MANUAL TRANSAXLE: Y4M/Y4M-HD
MANUAL TRANSAXLE (571)
TRANSAXLE GEAR (572)
GEAR SHIFT COVER & FORK (573)
DIFFERENTIAL GEAR (574)
SHIFT CONTROL (575)
FIVE-SPEED MANUAL TRANSAXLE: D24, D33
MANUAL TRANSAXLE (561)
TRANSAXLE GEAR (563)
BEARING PLATE (565)
GEAR SHIFT COVER & FORK (566)
DIFFERENTIAL GEAR (567)
SHIFT CONTROL (569)
6. Steering
POWER STEERING SYSTEM
POWER STEERING GEAR (621)
POWER STEERING PIPE LINE (623)
MANUAL STEERING GEAR
MANUAL STEERING GEAR (635)
STEERING WHEEL & COLUMN
STEERING WHEEL (641)
STEERING COLUMN COVER (642)
STEERING COLUMN (643)
TIRE ROD (647)
7. (HVAC) Heating, Ventilation, and Air Conditioning
HEATING & VENTILATION
AIR DISTRIBUTION (711)
EVAPORATOR (713)
BLOWER (714)
HVAC CONTROL
COMPRESSOR (732)
COMPRESSOR MOUNT (733)
A/C HOSE & PIPE LINE (734)
A/C CONTROL SWITCH (735)
8. Restraints
SEAT BELTS
FRONT SEAT BELT (812)
REAR SEAT BELT (822)
SUPPLEMENTAL INFLATABLE RESTRAINTS
AIR BAG SYSTEM (832)
IMMOBILIZER (833)
9. Body and Accessories
BODY WIRING SYSTEM
WIRING HARNESS (911)
LIGHTING SYSTEM
FRONT LAMP (916/917)
REAR LAMP (918)
WIPER/WASHER SYSTEM
WINDSHIELD WIPER (921)
WINDSHIELD WASHER (923)
INSTRUMENT DRIVER SYSTEM
INSTRUMENT CLUSTER (925)
AUDIO & ANTI-THEFT SYSTEM
ELECTRICAL PARTS (928)
ANTENNA (929)
INTERIOR TRIM
INSTRUMENT PANEL (931)
MOLDING & SWITCH (932)
INSTRUMENT PARTS (933)
CONSOLE (934)
FRONT DOOR TRIM (935)
REAR DOOR TRIM (936)
PILLAR TRIM (938)
FLOOR CARPET (939)
SEATS
FRONT SEAT (941)
REAR SEAT (942)
GLASS & MIRRORS
GLASS & OUT SIDE MIRRORS (946)
EXTERIOR PARTS
EMBLEM & LETTERING (951)
MUD GUARD (952)
BUMPERS & FASCIAS
FRONT BUMPER (956)
REAR BUMPER (957)
DOORS
FRONT DOOR & LOCK (961A)
FRONT WINDOW LIFTER (961B)
FRONT WEATHERSTRIP (961C)
REAR DOOR & LOCK (963A)
REAR WINDOW LIFTER (963B)
REAR WEATHERSTRIP (963C)
FUEL FILLER LOCK & QUARTER WINDOW LOCK (966)
TRUNK LID LOCK & TAILGATE LOCK (967)
CAR LOCK (968)
ROOF
HEADLINING & ROOF PANEL (971)
SUNSHADE & INSIDE MIRROR (972A)
SUN ROOF (972B)
BODY FRONT END
HOOD PANEL (973)
FRONT PANEL (974)
FENDER PANEL (975)
DASH PANEL & COWL (976)
GRILLE (977)
BODY REAR END
TRUNK LID PANEL & SPOILER (978)
10. Paint
10 Paint
10 Paint Exterior
PRE-DELIVERY INSPECTION
FOREWORD
GENERAL INTRODUCTION
1. EQUIPMENT AND MATERIAL FOR PDI AND SERVICE
TOOLS
FLUIDS
2. PRE-DELIVERY INSPECTION FORM
ENGINE COMPARTMENT
1. COMPONENTS CONNECTION LOOSE
2. HOSE AND ELECT. WIRES ROUTING
3. FREENESS OF MOVEMENT OF LINKAGE, VALVES AND OTHER COMPONENTS
4. UNUSUAL NOISES
5. SEEPAGE AND LEAKS AT HOSES AND PIPE CONNECTIONS, ETC.
6. POWER STEERING SYSTEM
7. ENGINE COOLANT PROTECTION
8. ALL FLUID LEVELS CHECK
9. THROTTLE LINKAGE
10. BELTS TENSION
BODY - ACCESSORIES
1. HEADLIGHTS OPERATION AND AIM
2. TURN SIGNAL LIGHTS
3. HAZARD WARNING LIGHTS
4. BACK-UP LIGHTS
5. STOP LIGHTS
6. TAIL LIGHTS, POSITION LIGHTS, LICENSE PLATE LIGHTS, ADDITIONAL TURN SIGNAL LIGHTS
7. INSTRUMENT PANEL WARNING LAMPS AND INDICATORS
8. DOME AND COURTESY LIGHTS
OPTION
11. INSTRUMENT PANEL GAUGE OPERATION
14. REAR WINDOW AND OUTSIDE MIRROR DEMISTER BUTTON
16. HORN SWITCH
17. WIPER AND WASHER OPERATION
20. CUP HOLDER
21. CIGARETTE LIGHTER
22. CLOCK
23. DOOR LOCK
24. DOOR WINDOW
25. OUTSIDE REARVIEW MIRRORS
28. SEAT
29. FUEL FILLER DOOR RELEASE LEVER
30. TRUNK LID RELEASE LEVER
31. ENGINE HOOD RELEASE LEVER
34. SUNGLASSES HOLDER
UNDER VEHICLE
UNDER VEHICLE INSPECTION
1. STEERING GEAR AND LINKAGE
2. PROPER TIE ROD CLAMP POSITION
3. EXHAUST SYSTEM FOR PROPER ALIGNMENT AND CLEARANCE
4. FRONT AND REAR SUSPENSION
5. CHECK AXLE AND MANUAL TRANSMISSION FLUID LEVEL
6. BRAKE SYSTEM
7. FUEL SYSTEM
8. DRIVE SHAFT OF FRONT DRIVE AXLES
9. VISUALLY INSPECT WHEEL STUD AND FLANGE NUTS
10. INFLATE TIRES TO SPECIFIED PRESSURE
ROAD TEST
1. SEAT BELTS
2. FREE PLAY OF BRAKE AND CLUTCH
3. HORN
4. WIND NOISE
5. OPTIONS AND ACCESSORIES
6. HEATER AND AIR CONDITIONING
CONTROL PANEL
INCLUDES AIM WASHER IF NECESSARY
8. ENGINE AND TRANSMISSION PERFORMANCE DURING ACCELERATION, DECELERATION, IDLE, CRUISE AND DOWN SHIFTS
9. SQUEAKS AND RATTLES
10. STEERING COLUMN IGNITION LOCK
11. INSTRUMENTS AND GAUGES
12. THROTTLE CONTROL FOR FREE OPERATIONS
WHEEL CENTER POSITION AND HANDLING
INCLUDES PARKING BRAKE AND WARNING LIGHT
APPEARANCE
1. INSPECT CONDITION AND PERFORM DETAIL OPERATION
2. CHECK FOR PROPER ASSEMBLY, FIT AND RETENTION OF PARTS AND COMPONENTS
3. EXTERIOR FINISH
4. INTERIOR TRIM AND CARPETS PROTECTIVE COVERINGS
5. SPARE WHEEL, JACK AND VEHICLE TOOLS
6. BATTERY
ANNEX
1. RECEIVING INSPECTION
2. DIRECTION FOR THE USE OF HY-600 TRANSIT COATING REMOVER IN A HAND WASH OPERATION
3. STORAGE AND MAINTENANCE OF NEW VEHICLE IN EXTREMELY HOT AND HUMID LOCATIONS
DESCRIPTION:
SERVICE MANUAL
0. General Information
SPECIFICATIONS
Technical Data
Vehicle Dimensions and Weights
Standard Bolt Specifications
MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
Normal Vehicle Use
Explanation of Scheduled Maintenance Services
Scheduled Maintenance Charts
OWNER INSPECTIONS AND SERVICES
While Operating The Vehicle
At Each Fuel Fill
At least Monthly
At least Twice a Year
Each Time The Oil is Changed
At Least Annually
Recommended Fluids and Lubricants
GENERAL DESCRIPTION AND SYSTEM OPERATION
General Repair Instructions
GENERAL DESCRIPTION
Vehicle and Component Identification
Vehicle Lifting Procedures
1. Engine
GENERAL ENGINE INFORMATION
COMPONENT LOCATOR
Engine Compartment : 1.2 DOHC : B12D :
Engine Compartment : 1.4 DOHC : G14D :
DIAGNOSIS
General Diagnosis
GENERAL INFORMATION
Cleanliness and Care
On-Engine Service
ENGINE MECHANICAL : 1.2L DOHC
SPECIFICATIONS
Engine Specifications
Fastener Tightening Specifcations
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
Engine Diagnosis
Symptoms
Compression Test
Valve Clearance Test
Oil Pressure Test
Oil Leak Diagnosis
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank : Crankshaft Will Not Rotate
Coolant in Combustion Chamber
Coolant in Engine Oil
Fuel in Engine Oil
Drive Belt Chirp
Drive Belt Squeal
Drive Belt Whine
Drive Belt Rumble
Drive Belt Vibration
Drive Belt Falls Off
Drive Belt Excessive Wear
COMPONENT LOCATOR
Cylinder Head
Cylinder Block
Manifold & Air Charging System
Timing System & Mount
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Air Filter
Air Cleaner Assembly
Accessory Belt and Tensioner
Intake Manifold
Exhaust Manifold
Cylinder Head Cover
Timing Chain System
Camshafts
Valve Spring
Cylinder Head and Gasket
Oil Pan
Oil Pump
Engine Mount
Engine Assembly
UNIT REPAIR
Accessory Parts
Cylinder Head
Camshaft
Valve Train Components
Piston / Ring / Connecting Rod
Engine Block
GENERAL DESCRIPTION AND SYSTEM OPERATION
Cylinder Head and Gasket
CrankShaft
Timing System
Oil Pump
Oil Pan
Exhaust Manifold
Intake Manifold
Valve Train
Piston & Connecting Rod Assembly
ENGINE MECHNICAL : 1.4 DOHC : G14D
SPECIFICATIONS
Engine Specifications
Faster Tightening Specifications
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
Engine Diagnosis
Symptoms
Cylinder Compression Test
Engine Oil Pressure Test
Oil Leak Diagnosis
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank : Crankshaft Will Not Rotate
Coolant in Combustion Chamber
Coolant in Engine Oil
Fuel in Engine Oil
Drive Belt Chirp
Drive Belt Squeal
Drive Belt Whine
Drive Belt Rumble
Drive Belt Vibration
Drive Belt Falls Off
Drive Belt Excessive Wear
COMPONENT LOCATOR
Cylinder Head
Cylinder Block
Intake/Exhaust/Timing System
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Air Filter Element
Air Cleaner Assembly
Accessory Belt and Tensioner
Intake Manifold
Exhaust Manifold
Cylinder Head Cover
Timing System
Camshaft Sprocket
Camshaft Adjuster
Camshaft Seal Ring
Camshaft
Valve Train : Cylinder Head Installed :
Valve Clearance
Cylinder Head and Gasket
Oil Indicator and Tube
Engine Oil and Filter Change
Oil Cooler
Oil Pan
Oil Pressure Relief Valve
Oil Overpressure Relief Valve
Oil Pump
Flywheel : M/T Only :
Flexible Plate : A/T Only :
Crankshaft Front Oil Seal Ring
Crankshaft Rear Oil Seal Ring
Engine Mount
Reaction Rod
Engine Assembly
UNIT REPAIR
Cylinder Head
Camshaft
Valve Train
Piston / Ring / Connecting-Rod
Crankshaft
GENERAL DESCRIPTION AND SYSTEM OPERATION
Intake and Exhaust Manifold
Valve Train
Cylinder Head
Crankshaft and Piston
Lubrication System
Timing System
Engine Block
ENGINE COOLING
SPECIFICATIONS
Cooling System Specification
Fastener Tightening Specifications
DIAGNOSIS
Thermostat Test
Cooling Systen Diagnosis
COMPONENT LOCATOR
Cooling System : 1.2L DOHC :
Cooling Fan : 1.4L DOHC : G14D :
Cooling System : 1.4L DOHC : G14D :
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Draining and Refilling the Cooling System
Thermostat : 1.2 DOHC : B12D :
Thermostat : 1.4 DOHC : G14D :
Water Pump : 1.2 DOHC : B12D :
Water Pump : 1.4 DOHC : G14D :
Electric Cooling Fan
Surge Tank
Radiator
GENERAL DESCRIPTION AND SYSTEM OPERATION
General Description
Radiator
Surge Tank
Water Pump
Thermostat
Electric Cooling Fan
Engine Coolant Temperature Sensor
Engine Block Heater
ENGINE ELECTRICAL
SPECIFICATIONS
Starter Specifications
Generator Specifications
Battery Specifications
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Starting & Charging System
COMPONENT LOCATOR
Starting System : 1.2 DOHC :
Starting System : 1.4 DOHC :
Charging System : 1.2 DOHC :
Charging System : 1.4 DOHC :
DIAGNOSIS
No Crank
Starter Motor Noise
Battery Load Test
Generator Output Test
Generator System Check
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Generator : 1.2 DOHC : B12D :
Generator : 1.4 DOHC : G14D :
Starter : 1.2 DOHC : B12D :
Starter : 1.4 DOHC : G14D :
Battery/Battery Tray
UNIT REPAIR
Generator : 1.2L DOHC/KDAC :
Generator : 1.4L DOHC/KDAC :
GENERAL DESCRIPTION AND SYSTEM OPERATION
Battery
Ratings
Reserve Capacity
Cold Cranking Amperage
Built : In Hydrometer
Charging Procedure
Charging Time Required
Charging A Completely Discharged Battery : Off The Vehicle :
Jump Starting Procedure
Generator
Charging System
Starter
Starting System
ENGINE CONTROLS : 1.2L DOHC
SPECIFICATIONS
Engine Data Display Tables
Engine Data Display Table Definitions
Fastener Tightening Specifications
Temperature Vs Resistance
SPECIAL TOOLS
Special Tools Table
SCHEMATIC AND ROUTING DIAGRAMS
ECM Wiring Diagram : Hatchback : - 1.2L DOHC
ECM Wiring Diagram : Notchback : - 1.2L DOHC
ECM Wiring Diagram : ALL : - 1.2L DOHC
Connector END View
COMPONENT LOCATOR
Component Locator : 1.2L DOHC :
DIAGNOSIS
SYSTEM DIAGNOSIS
Diagnostic Aids
Idle Learn Procedure
TEC : TOOTH ERROR CORRECTION : Learn Procedure
ON-Board Diagnostic System Check : 1.2L DOHC :
Multiple ECM Information Sensor DTCs Set
Engine Cranks But Will Not Run : 1.2L DOHC :
No Malfunction Indicator Lamp : 1.2L DOHC :
Malfunction Indicator Lamp On Steady : 1.2L DOHC :
Fuel System Diagnosis : 1.2L DOHC :
Fuel Pump Relay Circuit Check : 1.2L DOHC :
Main Relay Circuit Check : 1.2L DOHC :
Manifold Absolute Pressure Check : 1.2L DOHC :
Idle Air Control System Check : 1.2L DOHC :
Ignition System Check : 1.2L DOHC :
Engine Cooling Fan Circuit Check : 1.2L DOHC :
Data Link Connector Diagnosis : 1.2L DOHC :
Fuel Injector Coil Test
Fuel Injector Balance Test
TROUBLE CODE DIAGNOSIS : 1.2L DOHC :
Clearing Trouble Codes
Diagnostic Trouble Codes : 1.2L DOHC :
DTC P0031
DTC P0032
DTC P0037
DTC P0038
DTC P0107 : Manifold Absolute Pressure Sensor Low Voltage
DTC P0108 : Manifold Absolute Pressure Sensor High Voltage
DTC P0112
DTC P0113
DTC P0117
DTC P0118
DTC P0122
DTC P0123
DTC P0131 HO2S : Sensor 1 : Low Voltage
DTC P0137 HO2S : Sensor 2 : Low Voltage
DTC P0132 HO2S : Sensor 1 : High Voltage
DTC P0138 HO2S : Sensor 2 : High Voltage
DTC P0133
DTC P0139
DTC P0140
DTC P0171
DTC P0172
DTC P0261 Injector 1 Low Voltage
DTC P0264 Injector 2 Low Voltage
DTC P0267 Injector 3 Low Voltage
DTC P0270 Injector 4 Low Voltage
DTC P0262 Injector 1 High Voltage
DTC P0265 Injector 2 High Voltage
DTC P0268 Injector 3 High Voltage
DTC P0271 Injector 4 High Voltage
DTC P0300
DTC P0301
DTC P0302
DTC P0303
DTC P0304
DTC P0327
DTC P0335
DTC P0336
DTC P0337
DTC P0341
DTC P0342
DTC P0351 : Ignition Control Circuit 1 and 4 Fault
DTC P0352 : Ignition Control Circuit 2 and 3 Fault
DTC P0400 : Exhaust Gas Recirculation Flow Out of Limit
DTC P0401 : Exhaust Gas Recirculation Blocked
DTC P0402 : Exhaust Gas Recirculation Leaked
DTC P0403
DTC P0404
DTC P0405
DTC P0406
DTC P0420
DTC P0444 : EVAP Purge Control Circuit No Signal
DTC P0445 : EVAP Purge Control Circuit Fault
DTC P0462
DTC P0463
DTC P0480 : Low Speed Cooling Fan Relay Circuit Fault
DTC P0481 : High Speed Cooling Fan Relay Circuit Fault
DTC P0501
DTC P0505
DTC P0532
DTC P0533
DTC P0537 : Evaporator Temperature Sensor Low Voltage
DTC P0538 : Evaporator Temperature Sensor High Voltage
DTC P0562
DTC P0563
DTC P0601 : Engine Control Module Checksum Error
DTC P0604 : Engine Control Module RAM Error
DTC P0605 : Engine Control Module Write Error
DTC P0628
DTC P0629
DTC P0646
DTC P0647
DTC P0650
DTC P0656
DTC P0661
DTC P0662
DTC P1321 : Crankshaft Segment Period Tooth Error
DTC P1390
DTC P1396
DTC P1610
DTC P1611
DTC P1628
DTC P1629
DTC P1650
SYMPTOM DIAGNOSIS
Important Preliminary Checks
Intermittents
Hard Start
Surges or Chuggles
Lack of Power, Sluggishness, or Sponginess
Hesitation, Sag, Stumble
Cuts Out, Misses
Poor Fuel Economy
Rough, Unstable, or Incorrect ldle, Stalling
Excessive Exhaust Emissions or Odors
Dieseling, Run-on
Backfire
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Fuel Pressure Test
Fuel Tank
Fuel Pump & Fuel Sender
Fuel Filter
Fuel Rail and Injectors
Ignition Coil : DIS : & Bracket
Engine Coolant Temperature : ECT : Sensor
Throttle Position Sensor
Idle Air Control Valve : IACV :
Throttle Body
Front Heated Oxygen Sensor : HO2S1 :
Rear Heated Oxygen Sensor : HO2S2 :
Temperature-Manifold Absolute Pressure : T-MAP : Sensor
Exhaust Gas Recirculation : EGR : Valve
Exhaust Gas Recirculation : EGR : Pipe
Knock Sensor
Evaporative Emission : EVAP : Canister Vent
Evaporative Emission : EVAP : Canister
Evaporative Emission : EVAP : Canister Purge
Camshaft Position : CMP : Sensor
Camshaft Position : CKP : Sensor
Engine Control Module : ECM :
GENERAL DESCRIPTION AND SYSTEM OPERATION
Ignition System Operation
Electronic Ignition System Ignition Coil
Crankshaft Position Sensor
Camahaft Position Sensor
Idle Air System Operation
Fuel Control System Operation
Evaporative Emission Control System Operation
Evaporative Emission Canister
Positive Crankcase Ventilation System Operation
Engine Coolant Temperature Sensor
Throttle Position Sensor
Catalyst Monitor Oxygen Sensors
Exhaust Gas Recirculation Valve
Intake Air Temperature Sensor
Idle Air Control Valve
Manifold Absolute Pressure Sensor
Engine Control Module
Fuel Injector
Knock Sensor
Rough Road Sensor
Strategy : Based Diagnostics
EOBD Serviceability Issues
Serial Data Communications
ON-Board Diagnostic : EOBD :
Comprehensive Component Monitor Diagnostic Operation
Common EOBD Terms
Reading Diagnostic Trouble Codes
Primary System : Based Diagnostics
ENGINE CONTROLS : 1.4 DOHC : G14D
SPECIFICATIONS
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
SCHEMATIC AND ROUTING DIAGRAMS
ECM Wiring Diagram : G14D MT80 – 1 Of 8 :
ECM Wiring Diagram : G14D MT80 – 2 Of 8 :
ECM Wiring Diagram : G14D MT80 – 3 Of 8 :
ECM Wiring Diagram : G14D MT80 – 4 Of 8 :
ECM Wiring Diagram : G14D MT80 – 5 Of 8 :
ECM Wiring Diagram : G14D MT80 – 6 Of 8 :
ECM Wiring Diagram : G14D MT80 – 7 Of 8 :
ECM Wiring Diagram : G14D MT80 – 8 Of 8 :
Connector End View
DIAGNOSIS
SYSTEM DIAGNOSIS
Diagnostic System Check
Symptoms – Engine Controls
Intermittent Conditions
Hard Start
Surges/Chuggles
Lack Of Power, Sluggishness, Or Sponginess
Detonation/Spark Knock
Hesitation, Sag, Stumble
Cuts Out, Misses
Poor Fuel Economy
Rough, Unstable, Or Incorrect Idle And Stalling
Backfire
Dieseling, Run-On
Malfunction Indicator Lamp : MIL : Inoperative
Malfunction Indicator Lamp : MIL : Always On
Engine Cranks But Does Not Run
Fuel Pump Electrical Circuit Diagnosis
Fuel System Diagnosis
Fuel Injector Solenoid Coil Test
Fuel Injector Balance Test
Alcohol/Contaminants-In-Fuel Diagnosis
Electronic Ignition : EI : System Diagnosis
Scan Tool Does Not Power Up
Scan Tool Does Not Communicate with GMLAN Device
Engine Control Module Programming And Setup : G14D/G16D Gasoline Engine with MT80 Controller :
Idel Learn Procedure
Crankshaft Position : CKP : System Variation Learn or TEC : Tooth Error Correction : Learn Procedure
TROUBLE CODE DIAGNOSIS
DTC Type Definitions : G14D Engine :
Clearing Trouble Codes
Diagnostic Trouble Codes
DTC P0011, P0012, P0014, P0015, P0026, P0027
DTC P0016, P0017
DTC P0068
DTC P0076, P0077, P0079, P0080
DTC P0106
DTC P0107, P0108
DTC P0112, P0113
DTC P0117, P0118
DTC P0122, P0123, P0222, P0223, P2135
DTC P0125
DTC P0131, P0132, P0134, P0137, P0138, P0140
DTC P0133
DTC P0135, P0141
DTC P0171, P0172
DTC P0230
DTC P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271
DTC P0300, P0301, P0302, P0303, P0304
DTC P0315
DTC P0317, P1396, P1397 : With ABS :
DTC P0317, P1396, P1397 : Without ABS :
DTC P0324
DTC P0325
DTC P0335, P0336
DTC P0340, P0341, P0366
DTC P0351, P0352, P0353, P0354
DTC P0420
DTC P0452, P0453
DTC P0458, P0459
DTC P0461, P0462, P0463
DTC P0480, P0481
DTC P0502 : A/T only
DTC P0502 : M/T only
DTC P0506, P0507
DTC P0532, P0533
DTC P0562, P0563
DTC P0571
DTC P0598, P0599
DTC P0601, P0602, P0606, P0607, P060A, P060C, P060D, P2610
DTC P061A
DTC P0641, P0651
DTC P0646, P0647
DTC P0650
DTC P0685
DTC P0700
DTC P1137, P1166
DTC P1138, P2297
DTC P2101, P2119
DTC P2104, P2105, P2106, P2110
DTC P2122, P2123, P2127, P2128, P2138
DTC P2184, P2185
DTC U0073
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Fuel System Pressure Relief
Fuel Pressure Test
Fuel Tank
Fuel Pump Assembly
Fuel Filter
Fuel Rail and Injectors
Ignition Coil
Engine Coolant Temperature : ECT1 : Sensor 1
Engine Coolant Temperature : ECT : Sensor 2
Electric Throttle Controller : ETC :
Front Heated Oxygen Sensor : HO2S1 :
Rear Heated Oxygen Sensor : HO2S2 :
Manifold Air Pressure : MAP : Sensor
Intake Air Temperature : IAT : Sensor
Camshaft Position Actuator Solenoid Valve
Accelator Pedal Module : APM :
Knock Sensor
Evaporative Emission : EVAP : Canister Vent
Evaporative Emission : EVAP : Canister
EVAP Canister Purge Valve
Camshaft Position : CMP : Sensor
Crankshaft Position Sensor : CKP : Sensor
ECM
GENERAL DESCRIPTION AND SYSTEM OPERATION
Ignition System Operation
Electronic Igniton System Ignition Coil
Crankshaft Position Sensor
Camshaft Position Sensor
Fuel Control System Operation
Evaporative Emission Control System Operation
Evaporative Emission Canister
Positive Crankcase Ventilation System Operation
Engine Coolant Temperature Sensor
Throttle Position Sensor
Catalyst Monitor Oxygen Sensors
Intake Air Temperature Sensor
Electric Thermostat System
Throttle Actuator Control : TAC : System
Camshaft Actuator System
Manifold Absolute Pressure Sensor
Engine Control Module
Fuel Injector
Knock Sensor
Rough Road Sensor
Strategy-Based Diagnostics
EOBD Serviceability Issues
Serial Data Communications
On-Board Diagnostic : EOBD :
Comprehensive Component Monitor Diagnostic Operation
Common EOBD Terms
Reading Diagnostic Trouble Codes
Primary System-Based Diagnostics
ENGINE EXHAUST
SPECIFICATIONS
Fastener Tightening Specifications
COMPONENT LOCATOR
Exhaust System
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Catalytic Converter : 1.2 DOHC : B12D :
Catalytic Converter : 1.4 DOHC : G14D :
Exhaust Front Pipe
Muffler : Front
Muffler : Rear
GENERAL DESCRIPTION AND SYSTEM OPERATION
Exhaust System
Muffler
Catalytic Converters
2. Suspension
SUSPENSION DIAGNOSIS
DIAGNOSIS
General Diagnosis
Torque Steer
Tapered Roller Bearing
WHEEL ALIGNMENT
SPECIFICATIONS
Wheel Alignment Specifications
Difference Between Left and Right
Fastener Tightening Specifications
DIAGNOSIS
Tire Diagnosis
Radial Tire Lead /Pull
Vibration Diagnosis
Preliminary Inspection
Front Toe Adjustment
Front Camber and Caster Check
Rear Camber Check
Rear Toe Check
GENERAL DESCRIPTION AND SYSTEM OPERATION
Four Wheel Alignment
Toe
Caster
Camber
Steering Axis Inclination
Included Angle
Scrub Radius
Setback
Turning Angle
FRONT SUSPENSION
SPECIFICATIONS
General Specifications
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
Strut Dampener
Ball Joint and Knuckle
Excessive Friction Check
COMPONENT LOCATOR
Front Suspension
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Stabilizer Shaft Link
Strut Assembly
Control Arm
Steering Knuckle
Crossmember Assembly
Stabilizer Bar
UNIT REPAIR
Wheel Hub and Wheel Bearing
Control Arm Bushings
Front Strut Assembly
Front Control Arm Bushing : Rear :
GENERAL DESCRIPTION AND SYSTEM OPERATION
Front Suspension
REAR SUSPENSION
SPECIFICATIONS
Fastener Tightening Specifications
CONPONENT LOCATOR
Rear Suspension
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
Excessive Friction Test
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Shock Absorber
Springs and Insulators
Rear Axle Assembly
Wheel Bearing Spindle/Rear Hub Unit
UNIT REPAIR
Hub Bearing
GENERAL DESCRIPTION AND SYSTEM OPERATION
Rear Suspension
TIRES AND WHEELS
SPECIFICATIONS
Tire Size and Pressure Specifications
Inflation Pressure Conversion Pecifications
Fastener Tightening Specifications
DIAGNOSIS
Wheel Runout
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Wheel
On-Vehicle Balancing
UNIT REPAIR
Aluminum Wheel Porosity
Aluminum Wheel Refinishing
Off- Vehicle Balancing
Correcting Non- Uniform Tires
Tire and Wheel Match-Mounting
Tire Mounting and Dismouting
GENERAL DESCRIPTION AND SYSTEM OPERATION
Tire and Wheel Balancing
Tire Chain Usage
Replacement Tires
All Season Tires
Passenger Metric Sized Tires
Tire LAbel
Spare Tire
Wheels
Inflation of Tires
3. Driveline Axle
AUTOMATIC TRANSAXLE DRIVE AXLE
SPECIFICATIONS
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
COMPONENT LOCATOR
Front Drive Axle
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Drive Axle Assembly
UNIT REPAIR
Outer Joint Seal
Inner Tripod Seal
GENERAL DESCRIPTION AND SYSTEM OPERATION
Front Drive Axle
MANUAL TRANSAXLE DRIVE AXLE
SPECIFICATIONS
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
COMPONENT LOCATOR
Front Drive Axle
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Drive Axle Assembly
UNIT REPAIR
Outer Joint Seal
Cross Groove Joint Seal
GENERAL DESCRIPTION AND SYSTEM OPERATION
Front Drive Axle
4. Brakes
HYDRAULIC BRAKES
SPECIFICATIONS
General Specifcations
Fastener Tightening Specifications
COMPONENT LOCATOR
Brake System : ABS :
Brake System : NON-ABS :
DIAGNOSIS
Brake System Testing
Brake Hose Inspection
Warning Lamp Operation
Brake Lamp Warning Circuit Diagnosis
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Manual Bleeding the Brakes
Brake Hose : Rear :
Brake Hose : Front :
Stoplamp Switch
Brake Pedal
GENERAL DESCRIPTION AND SYSTEM OPERATION
Hydraulic Fluid
MASTER CYLINDER
SPECIFICATIONS
Fastener Tightening Specifications
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Master Cylinder Assembly
Brake Fluid Reservoir
Prorortilning Valve
UNIT REPAIR
Master Cylinder Overhaul
GENERAL DESCRIPTION AND SYSTEM OPERATION
Master Cylinder
Proportioning Valves
Fluid Level Sensor
POWER BOOSTER
SPECIFICATIONS
Fasrener Tightening Specifications
DIAGNOSIS
Power Booster Functional Check
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Vacuum Hose
Power Booster Assembly
GENERAL DESCRIPTION AND SYSTEM OPERATION
Power Booster
FRONT DISC BRAKES
SPECIFICATIONS
General Specifcations
Fastener Tightening Specirications
DIAGNOSIS
Lining Inspection
Rotor Inspection
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Shoe and Lining
Caliper Assembly
Rotor
Splash Shield
UNIT REPAIR
Caliper Overhaul
GENERAL DESCRIPTION AND SYSTEM OPERATION
Disc Brake Caliper Assembly
REAR DRUM BRAKES
SPECIFICATIONS
General Specifcations
Fastener Tightening Specifications
DIAGNOSIS
Lining Inspection
Drums
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Brake Adjustment
Shoe and Lining
Wheel Cylinder Assembly
Backing Plate
UNIT REPAIR
Wheel Cylinder
GENERAL DESCRIPTION AND SYSTEM OPERATION
Drum Brakes
ANTILOCK BRAKE SYSTEM
SPECIFICATIONS
General Specifications
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
SCHEMATIC AND ROUTING DIAGRAMS
ABS System Circuit
EBCM Connector Face View
COMPONENT LOCATOR
ABS System
DIAGNOSIS
Diagnostic Circuit Check
ABS Indicator Lamp Inoperative
Power Supply to Control Module, No DTCs Stored
ABS Indicator Lamp Illuminated Continuously, No DTCs Stored
Self-Diagnostics
Displaying DTCs
Clearing DTCs
Intermittents and Poor Connections
DTC C0035
DTC C0036
DTC C0040
DTC C0041
DTC C0045
DTC C0046
DTC C0050
DTC C0051
DTC C0060/C0065
DTC C0070/C0075
DTC C0080/C0085
DTC C0090/C0095
DTC C0110
DTC C0121
DTC C0161
DTC C0550
DTC C0800
DTC C1395
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Service Precautions
Bleeding System
ABS Modulator Assembly
Front Wheel Speed Sensor
Rear Wheel Speed Sensor
GENERAL DESCRIPTION AND SYSTEM OPERATION
Basic Knowledge Required
ABS System Components
Base Braking Mode
Antilock Braking Mode : Apply
Antilock Braking Mode : Hold
Antilock Braking Mode : Release
EBD : Electronic Brake Force Distribution : System
The Benefits of EBD
Electronic Brake-Force Distribution : EBD : Failure Matrix
HECU : Hydraulic Electronic Control Unit :
Solenoid Relay
Wheel Speed Sensors
ABS Warning Lamp
Brake Warning Lamp
PARKING BRAKE
SPECIFICATIONS
Fastener Tightening Specifications
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Parking Brake Adjustment
Parking Brake Lever
Parking Brake Cable
GENERAL DESCRIPTION AND SYSTEM OPERATION
Parking Brake
5. Transmissions/Transaxle
AISIN AUTOMATIC TRANSAXLE
SPECIFICATIONS
General Specifications
Transaxle Gear Ratio
Fluid Capacity
Line Pressure Specification
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
SCHEMATIC DIAGRAMS
Transmission Control Module : 1 of 4 :
Transmission Control Module : 2 of 4 :
Transmission Control Module : 3 of 4 :
Transmission Control Module : 4 of 4 :
Shift Lock Control
Shift Speed
COMPONENT LOCATOR
Shift Select Control
Automatic Transaxle Components
Bearing and Races Installation Position and Direction
DIAGNOSIS
Electric Connector View
Wiring Harness and Connector Inspection
Road Test
Function Check
Unit Inspection
On-Vehicle Repair : Matrix Chart :
Shift Lever Diagnosis
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
Diagnostic Trouble Code Chart
DTC P0562
DTC P0563
DTC P0601
DTC P0604
DTC P0705
DTC P0706
DTC P0711
DTC P0712
DTC P0713
DTC P0717
DTC P0722
DTC P0741
DTC P0742
DTC P0751
DTC P0752
DTC P0756
DTC P0757
DTC P0787
DTC P0788
DTC P0962
DTC P0963
DTC P0973
DTC P0974
DTC P0976
DTC P0977
DTC P2769
DTC P2770
DTC U0001
DTC U0100
DTC U0401
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Transaxle Fluid Level Checking Procedure
Fluid Drain Procedure
Locating Fluid Leaks
Case Porsity Repair
Fluid Cooler Flushing
Control Cable Adjustment
Shift Control Lever Assembly
BTSI Solenoid
Transmission Range : TR : Switch
Shift Control Cable
Shift Select Cover
Input Shaft Speed : ISS : Sensor
Output Shaft Speed : OSS : Sensor
Transmission Control Module : TCM :
Fluid Cooler Inlet Pipes and Hoses
Fluid Cooler Outlet Pipe and Hoses
Transaxle Assembly
UNIT REPAIR
Major Component Disassembly
Major Component Assembly
Oil Pump
Direct Clutch
Planetary Ring Gear
One-Way Clutch
Forward and Reverse Clutch
Counter Driven Gear
Valve Body
Differential Case
GENERAL DESCRIPTION AND SYSTEM OPERATION
Transaxle Description
Electronical Components
Hydraulic Control System
Automatic Transaxle System
FIVE-SPEED MANUAL TRANSAXLE : D16 :
SPECIFICATIONS
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
Isolate Noise
Symptom Diagnosis
COMPONENT LOCATORS
Gears and Case
Bearing Plate
Differential Gear
Shift Linkage
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Checking Fluid Level
Shift Linkage Adjustment
Gearshift Lever
Gearshift Lever Housing
Speedometer Driven Gear
Shift Linkage Assembly
Drive Axle Seal
Transaxle Assembly
UNIT REPAIR
Major Component Disassembly
Input Shaft and Cluster Gear
Mainshaft
Housing Case
Differential
Major Component Assembly
GENERAL DESCRIPTION AND SYSTEM OPERATION
Five-Speed Manual Transaxle
FIVE-SPEED MANUAL TRANSAXLE : Y4M HD :
SPECIFICATIONS
General Specifications
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
General Diagnosis
Checking Fluid Level
Changing Fluid
Checking Transaxle Noise
Checking Bearing Noise
COMPONENT LOCATORS
Gear Shift Control
Input Shaft and Counter Shaft Gear
Gear Shift Fork
Differential and Case
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Manual Transaxle Assembly
Speedometer Driven Gear
Gear Shift Control Cable
Gear Shift Control Lever
UNIT REPAIR
Gear Unit
Input Shaft
Counter Shaft
Gear Shift Fork
Differential
GENERAL DESCRIPTION AND SYSTEM OPERATION
Five-Speed Manual Transaxle
Reverse Gear Misshift Preventing Mechanism
Differential
CLUTCH : HYDRAULIC TYPE :
SPECIFICATIONS
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
Clutch Operation
COMPONENT LOCATOR
Hydraulic Clutch
Clutch Pedal
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Clutch Pedal
Air Bleeding
Pressure Plate and Clutch Disc
Clutch Master Cylinder Assembly
Clutch Release Cylinder Assembly
UNIT REPAIR
Clutch Master Cylinder
Clutch Release Cylinder
GENERAL DESCRIPTION AND SYSTEM OPERATION
Driving Members
Driven Members
Operating Members
CLUTCH : CABLE TYPE :
SPECIFICATIONS
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
General Diagnosis
Clutch Pedal Operation
Clutch Cable Adjustment
Clutch Cable
COMPONENT LOCATOR
Clutch Components
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Pressure Plate and Clutch Disc
Clutch Release Bearing, Shaft and Bushing
Clutch Release Arm
Clutch Cable
Clutch Pedal
GENERAL DESCRIPTION AND SYSTEM OPERATION
Driving Members
Driven Members
Operating Members
6. Steering
POWER STEERING SYSTEM
SPECIFICATIONS
Fastener Tighteming Specifications
SPECIAL TOOLS
Special Tools Table
COMPONENT LOCATOR
Power Steering System
DIAGNOSIS
Power Steering System Pressure Test
Power Steering System Leak Test
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Bleeding the Power Steering System
Checking and Adding Fluid
Fluid Reservoir
Power Steering Gear Cylinder Pipes
Power Steering Hoses and Pipes
Fluid Reservoir Suction Hose
GENERAL DESCRIPTION AND SYSTEM OPERATION
Power Steering System
POWER STEERING PUMP
SPECIFICATIONS
General Specifications
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
Power Steering Pump Diagnosis
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Serpentine Accessory Drive Belt : 1.4 & 1.5 FAM I Engine :
Power Steering Pump Belt : 1.4 Fam1Gen3 Engine :
Pump Assembly : 1.2 Engine :
Pump Assembly : 1.4 & 1.5 FAM I Engine :
Pump Assembly : 1.4 Fam1Gen3 Engine :
Pump Assembly Mounting Bracket : 1.4 Fam1Gen3 Engine :
GENERAL DESCRIPTION AND SYSTEM OPERATION
Power Steering Pump
Seals
POWER STEERING GEAR
SPECIFICATIONS
General Specifications
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
COMPONENT LOCATOR
Rack And PinionSteering Gear
DIAGNOSIS
Power Rack and Pinion Steering Gear
Power Rack and Pinion Steering Gear Bench Testing
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Rack and Pinion Assembly
Outer Tie Rod
Dust Boot
Straight-Ahead Check
GENERAL DESCRIPTION AND SYSTEM OPERATION
Power Rack and Pinion
MANUAL STEERING GEAR
SPECIFICATIONS
General Specifications
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
Manual Rack and Pinion Steering Gear
Straight-Ahead check
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Rack and Pinion assembly
Outer Tie Rod
Dust Boot
Straight-Ahead check
GENERAL DESCRIPTION AND SYSTEM OPERATION
Manual Rack and Pinion
STEERING WHEEL AND COLUMN
SPECIFICATIONS
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
DIAGNOSIS
Steering Column Diagnosis
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Turn Signal Switch and Lever
Wiper Switch and Lever
Steering Wheel with SIR
Ignition Lock Cylinder and Switch
Key Reminder Switch
Key Hole Illumination
Steering Column
GENERAL DESCRIPTION AND SYSTEM OPERATION
Steering Wheel and Column
Ignition Key Reminder
7. (HVAC) Heating, Ventilation, and Air Conditioning
HEATING AND VENTILATION SYSTEM
SPECIFICATIONS
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Non-A/C Diagrams
Airflow Through Vents With Rear Heating Duct*
DIAGNOSIS
HEATER SYSTEM
Insufficient Heating or Defrosting
Blower Electrical
Improper Air delivery or No Mode Shift
Too Much Heat
Controls
Blower Noise
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Temperature Cable Adjustment
Control Assembly
Blower Motor
Blower Resistor
Heater Hoses
Heater Core
Rear Heating
GENERAL DESCRIPTION AND SYSTEM OPERATION
Heating and Ventilation Systems
MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
SPECIFICATIONS
General Specifications : V5 System :
General Specifications : SP10 System :
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
SCHEMATIC AND ROUTING DIAGRAMS
A/C Refrigerant System : Typical :
A/C Airflow : Typical :
A/C Schematic
A/C Compressor Control : MT80
DIAGNOSIS
GENERAL DIAGNOSIS
Testing the Refrigerant System
Insufficient cooling "Quick Check" Procedure
A/C Performance Test : V5 System :
A/C Performance Test : SP10 System :
Pressure-Temperature Relationship of R-134A
Leak Testing The Refrigerant System
Air Conditioning System Diagnosis
Insufficient Cooling Diagnosis : 1.4D/1.5S V5 System :
Insufficient Cooling Diagnosis : 1.2 SOHC/DOHC SP10 System :
SYMPTOM DIAGNOSIS
Pressure Test Chart : R-134A System :
Low and High Side Pressure Relationship Chart
COMPONENT LOCATOR
V5 Compressor
SP10 Compressor
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
GENERAL A/C SYSTEM SERVICE PROCEDURES
O-ring Replacement
Handling Refrigerant
Handling of Refrigerant Lines and Fittings
Maintaining Chemical Stability In the Refrigeration System
Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System
SERVICEABLE COMPONENTS
HVAC Cables
Temperature Cable Adjustment
Control Assembly
Blower Motor
Blower Motor Resistor
A/C Pressure Transducer
A/C Compressor Relay
A/C Expansion Valve
Heater/Air Distribution Case Assembly
A/C High-Pressure Line
Heater Hoses
Heater Core
Evaporator Core
Compressor
Condenser : With Receiver-Dryer :
UNIT REPAIR
V5 AIR CONDITIONING COMPRESSOR OVERHAUL
Clutch Plate and Hub Assembly
Clutch Rotor and Bearing
Clutch Coil
Shaft Seal Replacement
Control Valve Assembly
Rear Head, Gasket, Valve Plate, Reed Plate, and O-ring
Cylinder-to-Front Head O-ring
Leak Testing : External :
SP10 AIR CONDITIONING COMPRESSOR OVERHAUL
Clutch & Drive Assembly
Pulley & Bearing Assembly
Coil & Housing Assembly
Clutch Function Test
GENERAL DESCRIPTION AND SYSTEM OPERATION
GENERAL INFORMATION
The A/C System
System Components-Functional
System Components-Control
V5 and SP10 Compressor-General Description
V5 Compressor-Description of Operation
SP10 Compressor-Description of Operation
AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
SPECIFICATIONS
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
HVAC : Full Automatic Temperature Control
DIAGNOSIS
GENERAL A/C DIAGNOSTICS
V5 SYSTEM AIR CONDITIONING AND AUTOMATIC TEMPERATURE CONTROL : ATC :
Self-Diagnostic Circuit Check
Automatic Temperature Controller Does Not Operate When Ignition Is ON
No Hot Air From Blower
No Cool Air From Blower
Blower Motor Does Not Run At All
DIAGNOSTIC TROUBLE CODES
Code 1 : In-Car Sensor Error
Code 2 : Ambient Air Temperature Sensor Error
Code 3 : Water Sensor Error
Code 4 : Air Mix Door Error
Code 5 : Sun Sensor Error
Code 8 : Intake Sensor Error
Code 10, 11 : Intake/Mode Door Error
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
GENERAL A/C SYSTEM SERVICE PROCEDURES
General Service Procedures
SERVICEABLE COMPONENTS
Common HVAC Components
Automatic Temperature Control Assembly
Inlet Air Door Motor
Mode Door Motor
Air Mix Door Motor
Water Sensor
Ambient Air Temperature Sensor
In-Car Temperature Sensor
Sun Sensor
Intake Sensor
UNIT REPAIR
V5 AIR CONDITIONING COMPRESSOR OVERHAUL
Compressor Overhaul
GENERAL DESCRIPTION AND SYSTEM OPERATION
GENERAL INFORMATION
The V5 System
System Components-Control
8. Restraints
SEAT BELTS
SPECIFICATIONS
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Driver Seat Belt Warning
DIAGNOSIS
Seat Belt Warning Lamp is Inoperative
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Pretensioner Front Seat Belt
Front Seat Belt Height Adjuster
Three-Point Rear Seat Belt : Notchback :
Three-Point Rear Center or Outboard Seat Belt : Hatchback :
Two-Point Rear Center Seat Belt and Buckle
Front Seat Belt Buckle : Equipped with Seat Recliner of Dial Type
Front Seat Belt Buckle : Equipped with Seat Recliner of Lever Type
Rear Seat Belt Buckle
GENERAL DESCRIPTION AND SYSTEM OPERATION
Driver Seat Belt Warning
Pretensioner Front Seat Belt : Only Western Europe :
Three-Point ELR Front and Rear Seat Belt
Two-Point LAP Rear Center Seat Belt
Operational and Functional Checks
SUPPLEMENTAL INFLATABLE RESTRAINTS : SIR :
SPECIFICATIONS
General Specifications
Fastener Tightening Specifications
SPECIAL TOOLS
SPECIAL TOOLS TABLE
SCHEMATIC AND ROUTING DIAGRAMS
Supplemental Inflatable Restraints : SIR : Electronical Schematic
SIR Component Locator
DIAGNOSIS
Diagnostic Trouble Code : DTC
Scan Tool Diagnostics
SIR Diagnostic System Check
Sensing and Diagnostic Module : SDM : Integrity Check
DTC B1101
DTC B1102
DTC B1103
DTC B1346
DTC B1347
DTC B1348
DTC B1349
DTC B1352
DTC B1353
DTC B1354
DTC B1355
DTC B1361
DTC B1362
DTC B1363
DTC B1364
DTC B1367
DTC B1368
DTC B1369
DTC B1370
DTC B1378
DTC B1379
DTC B1380
DTC B1381
DTC B1382
DTC B1383
DTC B1384
DTC B1385
DTC B1395
DTC B1400
DTC B1401
DTC B1402
DTC B1403
DTC B1404
DTC B1405
DTC B1409
DTC B1410
DTC B1414
DTC B1415
DTC B1451
DTC B1453
DTC B1620
DTC B1650
DTC B1651
DTC B1652
DTC B1657
DTC B2500
DTC B2502
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
SERVICE PRECAUTION
Disabling the Supplemental Inflatable Restraints : SIR :
Enabling the Supplemental Inflatable Restraints : SIR :
Handling, Installation and Diagnosis
Repairs and Inspections Required After an Accident
Accident With Deployment Components Replacements
Accident Without Deployment Component Inspection
Sensing and Diagnostic Module : SDM :
Driver Airbag Module
Clock Spring
Passenger Airbag Module
Passenger Airbag Cut-OFF Switch
Side Airbag Sensor
Front Seat Belt Pretensioner
Airbag Module Deployment : Inside of Vehicle :
Airbag Module Deployment : Outside of Vehicle :
Deployed Airbag Module disposal Procedure
SIR Wiring Repair
GENERAL DESCRIPTION AND SYSTEM OPERATION
Supplemental Inflatable Restraints : SIR :
Airbag Modules
Front Seat Belt Pretensioners
Passenger Airbag Manual Cut-Off Switch
Passenger Airbag "OFF" Lamp
Sensing and Diagnostic Module : SDM :
Airbag Warning lamp
Clock Spring
Wiring Harness Connectors
9. Body and Accessories
BODY WIRING SYSTEM
SCHEMATIC AND ROUTING DIAGRAMS
Power Distribution Schematic : Notchback :
Power Distribution Schematic : Hatchback :
Engine Room Relay and Fuse Block Locator
I/P Fuse Block Locator : Notchback :
I/P Fuse Block Locator : Hatchback :
Fuse Chart
Front Harness Routing : Notchback :
Front Harness Routing : Hatchback :
Rear Harness Routing : Notchback :
Rear Harness Routing : Hatchback :
Floor Harness Routing : Notchback :
Floor Harness Routing : Hatchback :
Instrument Harness Routing
Door Harness Routing
LIGHTING SYSTEMS
SPECIFICATIONS
Bulb Usage Chart
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Stop Lamp, Center High Mount Stop Lamp : CHMSL : & Reverse Lamp Circuit : Notchback :
Stop Lamp, Center High Mount Stop Lamp : CHMSL : & Reverse Lamp Circuit : Hatchback :
Instrument Panel Illumination Circuit : W/O Dimmer Control, Notchback :
Instrument Panel Illumination Circuit : W/O Dimmer Control, Hatchback :
Instrument Panel Illumination Circuit : W Dimmer Control, Notchback :
Instrument Panel Illumination Circuit : W Dimmer Control, Hatchback :
Front and Rear Fog Lamps Circuit : Notchback :
Front and Rear Fog Lamps Circuit : Hatchback :
Head Lamps and Head Lamp Leveling Device : HLLD : Circuit : Notchback :
Head Lamps and Head Lamp Leveling Device : HLLD : Circuit : Hatchback :
Daytime Running Lamps Circuit : Notchback :
Daytime Running Lamps Circuit : Hatchback :
Parking, Tail and License Lamps Circuit : Notchback :
Parking, Tail and License Lamps Circuit : Hatchback :
Turn and Hazard Lamps Circuit : Notchback :
Turn and Hazard Lamps Circuit : Hatchback :
Lamps : Room, Door Opening Warning : Circuit : Notchback :
Lamps : Room, Door Opening Warning : Circuit : Hatchback :
Battery Saver Circuit : Notchback :
Battery Saver Circuit : Hatchback :
DIAGNOSIS
Headlamps
Daytime Running Lamps
Parking lamps and Taillamps
Interior Courtesy and Luggage Compartment Lamps
Fog Lamps
GENERAL DESCRIPTION AND SYSTEM OPERATION
Headlamps-On Reminder Chime
Headlamps
Parking and Turn Signal Lamps
Fog Lamps
Tail Lamps
License Plate Lamp
Interior Courtesy Lamp
Luggage Compartment Lamp
Backup Lamps
HORN
SPECIFICATIONS
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Horn, Power Jack, Ashtray Lamp & Cigar Lighter Circuit : Notchback :
Horn, Power Jack, Ashtray Lamp & Cigar Lighter Circuit : Hatchback :
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Horn
GENERAL DESCRIPTION AND SYSTEM OPERATION
Horn
WIPERS/WASHER SYSTEMS
SPECIFICATIONS
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Wiper Circuit : Notchback :
Wiper Circuit : Hatchback : - Rear Wiper : W/INT :
DIAGNOSIS
Intermittent Windshield Wipers
Windshield Washer System
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Windshield Wiper Arm : Typical :
Windshield Wiper Motor
Windshield Wiper Blade
Windshield Wiper Blade Insert
Windshield Washer Reservoir
Windshield Washer Pump
Windshield Washer Nozzles
Windshield Washer Hoses
GENERAL DESCRIPTION AND SYSTEM OPERATION
Windshield Wiper System
Windshield Washer System
INSTRUMENTATION/DRIVER INFORMATION
SPECIFICATIONS
Fastener Tightening Specifications
Instrument Cluster Indicator Lamps Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Instrument Cluster Circuit : 1 of 3 :
Instrument Cluster Circuit : 2 of 3 :
Instrument Cluster Circuit : 3 of 3 :
Clock Circuit
Instrument Panel Illumination Circuit : W/O Dimmer Control :
Instrument Panel Illumination Circuit : W/ Dimmer Control :
Key Reminder Circuit
Power Jack & Cigar Lighter Circuit
DIAGNOSIS
Cigar Lighter
Digital Clock
Instrument Panel Illumination
Fuel Gauge
Temperature Gauge
Instrument Cluster Indicator Lamps
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Cigar Lighter
Ashtray
Cupholder
Center Vents
Glove Box
Digital Clock
Instrument Cluster
Instrument Cluster Indicator Lamps
Instrument Panel
Smart Junction Box
GENERAL DESCRIPTION AND SYSTEM OPERATION
Cigar Lighter
Ashtray
Instrument Panel Vents
Glove Box
Digtal Clock
Instrument Cluster
Speedometer/Odometer/Trip Odometer
Fuel Gauge
Temperature Gauge
Instrument Cluster Indicator Lamps
Smart Junction Box
AUDIO SYSTEMS
SPECIFICATION
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Audio System Circuit
DIAGNOSIS
Stereo Cassette AM/FM Radio
Speakers
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Audio System
Front Speakers
Rear Speakers
Back Glass Antenna Module
Tweeter Speakers
Audio Remote Controller
GENERAL DESCRIPTION AND SYSTEM OPERATION
Stereo Cassette AM/FM Radio
Audio Security System : General Only :
Back Glass Antenna Module
Front and Rear Speakers
Tape Player and Cassette Care
Compact Disc Care
Setting the Area Code : General Only :
INTERIOR TRIM
SPECIFICATIONS
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Front Door Trim
Rear Door Trim
Upper B-Pillar Trim
Lower B-Pillar Trim
Upper Back Panel Shelf
Rear Door Interior Garnish Molding
Hatchback Door Lower Garnish Molding
Front Rocker Panel Cover
Rear Rocker Panel Cover
Floor Carpet
Floor Console
A-Pillar Trim
C-Pillar Trim
C-Pillar Trim : Hatchback :
Front Side Panel Trim : Three Door Hatchback :
Load Compartment Side Cover
Quarter Window Trim : Three Door Hatchback :
Front Door Escutcheon
Rear Side Panel Trim
Rear Side Panel Trim : Hatchback :
Rear Wheel House Trim
Lower Back Panel Cover
GENERAL DESCRIPTION AND SYSTEM OPERATION
Interior Trim Panels
Pressure Relief Vent
Floor Console
Floor Carpet
SEATS
SPECIFICATIONS
Fastener Tightening Specifications
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Front Bucket Seats
Head Restraint
Front Seatback : Dial Type :
Front Seatback : Lever Type : - General Only :
Front Seat Cushion
Front Seat Adjusters
Height Adjustment Knob
Front Seat Trim : Dial Type :
Front Seat Trim : Lever Type : - General Only :
Rear Seat Cushion
Split Rear Seatback
Rear Seatback Fold Striker
Rear Seatback Lock Assembly
Rear Seat : Hatchback :
Seat Covers
Child Seat Anchorage
GENERAL DESCRIPTION AND SYSTEM OPERATION
Seats
Child Seat Anchorage
WATERLEAKS
SPECIFICATIONS
Recommended Materials for Waterleak Repairs
Watertest Stand Specifications
DIAGNOSIS
Waterleak Diagnosis
MAINTENANCE AND REPAIR
On-Vehicle Service
Waterleak Repair
WINDNOISE
DIAGNOSIS
Windnoise Diagnosis
MAINTENANCE AND REPAIR
On-Vehicle Service
Windnoise Repair
SQUEAKS AND RATTLES
DIAGNOSIS
Squeak and Rattle Diagnosis
MAINTENANCE AND REPAIR
On-Vehicle Service
Squeak and Rattle Repair
GLASS AND MIRRORS
SPECIFICATIONS
Fastener Tightening Specifications
SPECIAL TOOLS
Special Tools Table
SCHEMATIC AND ROUTING DIAGRAMS
Rear Window and Outside Rear View Mirror Defogger
Electric Control Outside Rearview Mirror
DIAGNOSIS
Testing Rear Window Defogger Grid Line
Outside Rearview Mirror Defoggers
Electric Control Outside Rearview Mirror
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Windshield
Rear Window Glass
Rear Window Defogger Grid Line Repair
Rear window Defogger Braided Lead Wire Repair
Front Door Glass
Rear Door Glass
Inside Rearview Mirror Support
Inside Rearview Mirror
Outside Rearview Mirrors
GENERAL DESCRIPTION AND SYSTEM OPERATION
Stationary Glass
Inside Rearview Mirror
Outside Rearview Mirrors
EXTERIOR TRIM
SPECIFICATIONS
Fastener Tightening Specifications
MAINTENANCE AND REPAIR
On-Vehicle Service
Roof Molding
Rear Spoiler
Mud Guards
GENERAL DESCRIPTION AND SYSTEM OPERATION
Emblems and Lettering
Mud Guards
FRAME AND UNDERBODY
SPECIFICATIONS
Fastener Tightening Specifications
Underbody Dimensions
MAINTENANCE AND REPAIR
ON-Vehicle Service
Alignment Checking
Floor Pan Insulators
Engine Under Covers
GENERAL DESCRIPTION AND SYSTEM OPERATION
General Body Construction
Engine Under Covers
BUMPERS AND FASCIAS
SPECIFICATIONS
Fastener Tightening Specifications
MAINTENANCE AND REPAIR
On-Vehicle service
Front Bumper Fascia
Front Bumper Impact Beam
Front Bumper Fascia : Hatchback :
Front Bumper Impact Beam : Hatchback :
Rear Bumper Fascia
Rear Bumper Fascia : Hatchback :
GENERAL DESCRIPTION AND SYSTEM OPERATION
Bumpers
DOORS
SPECIFICATIONS
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Power Door Locks Circuit
Power Windows Circuit : Front Only :
Power Windows Circuit : Front and Rear :
Power Windows Circuit : Front and Rear : With Safety Funtion :
DIAGNOSIS
Power Windows
Windows Motor Reprogramming
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Front Door Glass Run
Rear Door Glass Run
Front Door Secondary Weatherstrip
Rear Door Secondary Weatherstrip
Door Lock Striker
Door Lock Striker Adjustment
Front Door Lock
Childproof Rear Door Lock
Inside Door Handle
Inside Lock Rod
Outside Door Handle
Door Lock Cylinder
Power Window Regulator
Manual Front Window Regulator
Manual Rear Window Regulator
Front Door Assembly
Rear Door Assembly
Door Hinge
Door Hold Open Link
Inside Channel Molding
Outside Channel Molding
Door Weatherstrip
Door Seal Trim
Door Opening Weatherstrip
Manual Window Regulator Handle
GENERAL DESCRIPTION AND SYSTEM OPERATION
Door Lock Striker
Childproof Rear Door Lock
Power Door Locks
Power Windows
ROOF
SPECIFICATIONS
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Power Sunroof System
DIAGNOSIS
Power Sunroof
MAINTENANCE AND REPAIR
On-Vehicle Service
Power Sunroof
Interior Courtesy Lamp/Power Sunroof Control Switch
Formed Headliner
Sun Visors
Passenger Assist Handles
GENERAL DESCRIPTION AND SYSTEM OPERATION
Roof
Power Sunroof
Power Sunroof Control Switch
Sun Visors
Passenger Assist Handles
Coat Hook
BODY FRONT END
SPECIFICATIONS
Fastener Tightening Specifications
MAINTENANCE AND REPAIR
On-Vehicle Service
Lubrication
Fasteners
Anticorrosion Materials
Front End Sealing
Cowl Vent Grille
Hood
Hood Hinges
Hood Prop Rod
Hood Secondary Latch
Hood Latch Release Cable
Radiator Grille
Radiator Grille : Hatchback :
Fender
Fender and Fender Liner : Hatchback :
Fender Molding : Hatchback :
GENERAL DESCRIPTION AND SYSTEM OPERATION
Body Front End
BODY REAR END
SPECIFICATIONS
Fastener Tightening Specifications
MAINTENANCE AND REPAIR
On-Vehicle Service
Fuel Filler Door
Fuel Filler Door Remote Cable and Handle
Rear Deck Lid
Rear Deck Lid Remote Cable and Handle
Torque Rod
Luggage Compartment Lock Cylinder
Luggage Compartment Lock Striker
Luggage Compartment Lock
Weatherstrip
GENERAL DESCRIPTION AND SYSTEM OPERATION
Fuel Filler Door
Rear Deck Lid
REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM
SPECIFICATIONS
Fastener Tightening Specifications
SCHEMATIC AND ROUTING DIAGRAMS
Remote Keyless Entry and Anti-Theft System
Control Module/Receiver Connector
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Control Module/Receiver
Control Module/Receiver : Hatchback :
Siren : General Only :
Hood Open Switch
Remote Keyless Entry Transmitter Programming
GENERAL DESCRIPTION AND SYSTEM OPERATION
Remote Keyless Entry and Anti-Theft System
Remote Locking and Unlocking
Security Indicator
Intrusion Sensing
Siren : General Only :
Vehicle Locator
Autolocking : Safety Lock :
Fault or Alarm Indication
Control Module/Receiver
IMMOBILIZER ANTI-THEFT SYSTEM
SCHEMATIC AND ROUTING DIAGRAMS
Immobilizer Anti-Theft System
DIAGNOSTIC INFORMATION AND PROCEDURES
Immobilizer System : MR-140, HV-240, SIRIUS D4, SIRIUS D42 :
DTC P1626 : HV-240, MR-140/ Except Euro IV : , U0167 : MR-140/ Euro IV Only : , P1628 : SIRIUS D4, SIRIUS D42 :
DTC P1631 : MR-140, HV-240 : , P1629 : SIRIUS D4, SIRIUS D42 :
MAINTENANCE AND REPAIR
On-Vehicle Service
Key Coding Procedure
ID Code Reprogramming
Transponder
Immobilizer Control Unit
GENERAL DESCRIPTION AND SYSTEM OPERATION
Immobilizer System
Electronically Coded Keys
Detection Coil
Immobilizer Control Unit
Serial Data Link
Electronic Control Moudle : ECM :
Security Indicator