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POWER STEERING – POWER STEERING SYSTEM

PS–1

POWER STEERING SYSTEM ON-VEHICLE INSPECTION 1.

CHECK STEERING EFFORT (TORQUE) NOTICE: Some of these service operations may affect the SRS airbags. Read the precautionary notices concerning the SRS airbags before servicing. (a) Stop the vehicle on a level, paved road and align the wheels facing straight ahead. (b) Disconnect the cable from the negative battery terminal. (c) Remove the steering pad (See page RS-309). (d) Connect the cable to the negative battery terminal. (e) Using a torque wrench, check that the steering wheel set nut is properly tightened. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (f) Turn the ignition switch to ON (the engine is stopped) so that the power steering is ready to operate. (g) Turn the steering wheel 90 degrees to the right and check the steering effort (torque) while turning. Check the opposite direction in the same manner. Steering effort (Reference): 5.5 N*m (56 kgf*cm, 49 in.*lbf) (h) Align the front wheels facing straight ahead. (i) Disconnect the cable from the negative battery terminal. (j) Install the steering pad (See page RS-310). (k) Connect the cable to the negative battery terminal. (l) Clear the DTCs (See page RS-38). (m) Inspect the airbag warning light (See page RS-31).

F100174

2.

CHECK STEERING WHEEL FREE PLAY (a) Turn the ignition switch to ON so that the power steering is ready to operate. (b) Align the wheels facing straight ahead. (c) Gently turn the steering wheel right and left with your finger and check the steering wheel freeplay. Maximum freeplay: 30 mm (1.18 in.) HINT: If the freeplay is outside the specifications, replace intermediate shaft No. 2 or the steering gear with a new one.

PS


PS–2

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

ELECTRONIC POWER STEERING SYSTEM PRECAUTION 1.

PS

HANDLING PRECAUTION (a) When handling the electronic parts; • Avoid any impact to parts such as ECUs and relays. Replace with new ones if dropped or subjected to a severe blow. • Do not expose to high temperatures or humidity. • Do not touch the connector terminals, in order to prevent deformation or malfunctions due to static electricity. • When the power steering ECU has been replaced with a new one, perform the torque sensor zero point calibration. (See page PS-12 ) (b) When handling the steering column assembly; • Avoid any impact to the steering column assembly, especially to the motor and torque sensor. Replace with new ones if dropped or subjected to a severe blow. • Do not pull the wire harness when moving the steering column assembly. • When the steering column assembly has been replaced, perform the torque sensor zero point calibration after initializing the torque sensor zero point. (See page PS-12 ) (c) When disconnecting and reconnecting the connectors; • When disconnecting the connectors related to the electronic power steering system, turn the ignition switch on, center the steering wheel, turn the ignition switch off, and then disconnect the connectors. • When reconnecting the connectors related to the electronic power steering system, ensure that the ignition switch is off. Center the steering wheel and then turn the ignition switch on. NOTICE: Do not turn the ignition switch on when the steering wheel is not centered. • If the above operations are not carried out properly, the steering center point (zero point) will deviate, which may lead to a difference in steering effort between turning right and left. If there is a difference in steering effort between turning right and left, perform the torque sensor zero point calibration. (See page PS-12 )


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

2.

PS–3

PRECAUTIONS FOR CAN COMMUNICATION (a) CAN communication lines are used to receive information from the skid control ECU (ABS ECU) and the ECM, and to transmit warnings to the combination meter. When there are any problems in the CAN communication lines, DTCs of the CAN communication line are output. (b) Perform troubleshooting of the communication line problems when the CAN communication DTCs are output. Be sure to start troubleshooting on the electronic power steering system after confirming that the CAN communication system is normal. (c) Since the CAN communication line has its own length and route, it cannot be repaired temporarily with the bypass wire, etc.

PS


PS–4

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PARTS LOCATION HATCHBACK: POWER STEERING ECU

COMBINATION METER - P/S WARNING LIGHT

DLC3

MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK) - ECU-IG FUSE

PS

C117896E02


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

HATCHBACK:

PS–5

STEERING COLUMN ASSEMBLY

STEERING MOTOR ASSEMBLY

ENGINE ROOM R/B - EPS FUSE

C117899E02

PS


PS–6

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

SEDAN:

COMBINATION METER - P/S WARNING LIGHT

POWER STEERING ECU

DLC3

MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK) - ECU-IG FUSE

C138624E03

PS


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–7

SEDAN:

STEERING COLUMN ASSEMBLY STEERING MOTOR ASSEMBLY

ENGINE ROOM R/B - EPS FUSE

C138622E02

PS


PS–8

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

SYSTEM DIAGRAM w/ ABS:

12V

Power Steering ECU

Combination Meter

Torque Sensor Warning Signal

Power Steering Motor

Skid Control ECU

Vehicle Speed Signal DLC3 ECM

Engine Revolution Signal

: CAN Communication Line

C122330E01

PS


PS–9

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

w/o ABS:

12V

Power Steering ECU Torque Sensor

ECM

Engine Revolution Signal Power Steering Motor

Warning Signal

Combination Meter

DLC3

Vehicle Speed Signal

: CAN Communication Line

C122331E01

PS


PS–10

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

SYSTEM DESCRIPTION 1.

PS

DESCRIPTION The EPS (Electronic Power Steering) system generates torque through the operation of the motor and the reduction gear installed on the column shaft in order to assist power steering effort. The power steering ECU determines the direction and the amount of assisting power in accordance with the vehicle speed signals and signals from the torque sensor built into the steering column assembly. As a result, steering effort is controlled to be light during low speed driving and moderately high during high speed driving. (a) Power steering ECU: The power steering ECU calculates assisting power based on steering torque signals from the torque sensor and vehicle speed signals from the skid control ECU. For vehicles without ABS, the power steering ECU receives vehicle speed signals from the speedometer. (b) Torque sensor: The torque sensor detects the steering effort generated when the steering wheel is turned and converts it to an electrical signal. (c) EPS motor: The EPS motor is activated by the current from the power steering ECU and generates torque to assist the steering effort.


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–11

HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting according to the following flowchart. HINT: For further details, see the page given. The intelligent tester can be used in steps 3, 4, 7, 10 and 13.

1

VEHICLE BROUGHT TO WORKSHOP

NEXT

2

CUSTOMER PROBLEM ANALYSIS

NEXT

3

CHECK DTC AND FREEZE FRAME DATA (a) Record DTCs and freeze frame data. (See pagePS-25 )

NEXT

4

CLEAR DTC AND FREEZE FRAME DATA HINT: Clear DTC and FREEZE FRAME DATA (See page PS-25 ).

NEXT

5

PROBLEM SYMPTOM CONFIRMATION SYMPTOM DOES NOT OCCUR: GO TO STEP 6 SYMPTOM OCCURS: GO TO STEP 7

6

SYMPTOM SIMULATION

NEXT

7

CHECK DTC (a) Recheck for DTCs (See page PS-25 ). HINT: • Refer to the diagnostic trouble code chart when any DTCs are output.

PS


PS–12

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

• When any CAN communication system DTCs are output, perform troubleshooting on the CAN communication system first. • When communication to the power steering ECU is not established through the intelligent tester, inspect terminals SIL of the DLC3 and the power steering ECU, and the IG circuit of the power steering ECU. NORMAL SYSTEM CODE OUTPUT: GO TO STEP 8 DTC OUTPUT: GO TO STEP 9

8

PROBLEM SYMPTOMS TABLE HINT: Refer to PROBLEM SYMPTOMS TABLE (See page PS-21 ).

NEXT

9

DTC CHART HINT: Refer to DIAGNOSTIC TROUBLE CODE CHART (See page PS-29 ).

NEXT

10

CIRCUIT INSPECTION

NEXT

11

PROBLEM IDENTIFICATION

NEXT

12

REPAIR OR REPLACE

NEXT

13 NEXT

PS END

CONFIRMATION TEST


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–13

CALIBRATION 1.

TORQUE SENSOR ZERO POINT CALIBRATION (USING INTELLIGENT TESTER) NOTICE: Perform the torque sensor zero point calibration when any of the following conditions occur. • The steering column assembly (containing the torque sensor) has been replaced. • The power steering ECU has been replaced. • The steering wheel has been replaced. • The steering gear assembly has been replaced. • There is a difference in steering effort between turning right and left. (a) Center the steering wheel and align the front wheels straight ahead. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch on and turn the tester on. (d) Initialize the torque sensor zero point calibration signal and perform the zero point calibration by following the prompts on the tester screen. (e) Confirm that no DTCs are output after the zero point calibration is completed. 1. When DTC C1515/15 is output, see page PS-35. 2. When DTC C1516/16 is output, see page PS-36. 3. When DTC C1534/34 is output, see page PS-40. NOTICE: Do not touch the steering wheel during the calibration.

PS


PS–14

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

[5]

[1]

[ENTER]

[YES]

PS A F047677E01


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–15

A

[ENTER]

[ENTER]

PS F047678E01


PS–16

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

[5]

[2]

[ENTER]

C1515 and C1581.

[ENTER]

PS B C124987E01


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–17

B

[ENTER]

[YES]

[ENTER]

PS F047680E01


PS–18

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

2.

CG

DLC3:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TS

TC

F100115E28

P/S Warning Light 4Hz Blink 0.125 seconds

0.125 seconds

ON OFF F100306E02

PS

TORQUE SENSOR ZERO POINT CALIBRATION (USING SST CHECK WIRE) (a) Center the steering wheel and align the front wheels straight ahead. (b) Initialize the torque sensor zero point calibration signal. HINT: If the power steering ECU is replaced, initialization is not necessary. (1) Stop the vehicle and turn the ignition switch off. (2) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (3) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch on. (5) Disconnect and reconnect terminal TC of the DLC3 20 times or more within 20 seconds. (6) Check that DTC C1515/15 is output. (c) Perform the torque sensor zero point calibration. NOTICE: Do not touch the steering wheel during the calibration. HINT: Check whether any DTCs except C1515/15 are output. (1) Stop the vehicle and turn the ignition switch off. (2) Using SST, connect terminals TS and CG of the DLC3 and turn the ignition switch on. SST 09843-18040 (3) Wait for 7 seconds after the P/S warning light comes on. (4) Confirm that the P/S warning light blinks at intervals of 0.125 seconds (4Hz blink). (5) Disconnect the SST. SST 09843-18040 (6) Confirm that no DTCs are output. 1. When DTC C1515/15 is output, see page PS35. 2. When DTC C1516/16 is output, see page PS36. 3. When DTC C1534/34 is output, see page PS40.


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–19

TEST MODE PROCEDURE NOTICE: The torque sensor zero point calibration is performed automatically when the test mode inspection is conducted after the power steering ECU has been replaced with a new one. HINT: • Speed sensor signals can be checked easily in test mode. • Test mode code C1571/71 is stored during the transition to test mode. This code does not indicate a malfunction since the code will be cleared when the ECU determines that the sensor is normal. • The test mode code is cleared simultaneously when test mode is terminated. 1. TEST MODE START-UP (a) When using an intelligent tester; (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on and enter test mode by following the instructions on the tester screen. CG

DLC3:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TS

TC

F100115E28

P/S Warning Light Test Mode 0.125 seconds

0.125 seconds

ON OFF F100306E03

(b) When not using an intelligent tester; (1) Turn the ignition switch off and connect terminals 12 (TS) and 4 (CG) of the DLC3. SST 09843-18040 (2) Turn the ignition switch on. NOTICE: • Be sure to connect the correct terminals of the connector, otherwise a malfunction may occur. • If the torque sensor zero point calibration has not been performed, the torque sensor zero point calibration is performed automatically when test mode is entered. 2.

CHECK TEST MODE DISPLAY (a) The P/S warning light blinks as shown on the left when test mode is entered. NOTICE: If the torque sensor zero point calibration has not been performed, the P/S warning comes on until the torque sensor zero point calibration is completed, and shows the test mode blink pattern after the torque sensor zero point calibration is completed.

PS


PS–20

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

3.

CHECK VEHICLE SPEED SIGNAL (W/O ABS) (a) Drive the vehicle until the vehicle speed reaches 6 mph (10 Km/h) or more.

When system is normal:

mph (km/h)

6 (10)

Vehicle speed

0

P/S Warning light

Time

ON OFF 4Hz blink

Light blinks until test mode code C1571/71 cleared. Light goes off at 6 mph (10 km/h) or more.

C117900E01

4.

(b) When not using an intelligent tester; (1) Turn the ignition switch off. (2) Connect terminals 12 (TS) and 4 (CG) of the DLC3, and also terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040

CG

DLC3:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TS

PS

TC

READ TEST MODE CODE (a) When using an intelligent tester; (1) Check the DTCs in test mode. NOTICE: Test mode code is cleared when test mode is terminated.

F100115E28


PS–21

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

Normal Code (2Hz blink)

0.25

2

4

0.25

1.5

Codes 11 and 23

2.5

0.5 0.5 (Seconds) F100305E02

5.

(3) Read the number of times that the P/S warning light on the combination meter blinks. • To indicate the normal code, the P/S warning light comes on for 0.25 seconds at intervals of 0.25 seconds (2Hz blink). • When outputting a DTC, the P/S warning light displays it at intervals of 4 seconds. When outputting two or more DTCs, the P/S warning light displays each DTC at intervals of 2.5 seconds, and repeats from the first one 4 seconds after indicating the last one. • If two or more malfunctions are detected at the same time, DTCs are displayed in ascending numerical order. END OF TEST MODE (a) When using an intelligent tester; (1) Return to normal mode by following the instructions on the tester screen. (2) Turn the ignition switch off and disconnect the tester. (b) When not using an intelligent tester; (1) Turn the ignition switch off and disconnect terminals 13 (TC) and 4 (CG), and terminals 12 (TS) and 4 (CG) of the DLC3. SST 09843-18040 (2) Turn the ignition switch on.

TEST MODE CODE Code

C1571/71

Detection Item

Vehicle speed check

Conditions to clear code

Trouble areas

Vehicle speed 6 mph (10 Km/h) or more

If code cannot be cleared, any of following areas may malfunction. • Speed sensor • Combination meter • Power steering ECU • Wire harness and connector

PS


PS–22

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PROBLEM SYMPTOMS TABLE for Hatchback Symptom

Suspected area Front tires (improperly inflated, unevenly worn)

Heavy steering

While driving, steering effort does not change in accordance with vehicle speed or steering wheel does not return properly

Friction occurs when turning steering wheel during low speed driving High-pitched sound (squeaking) occurs when turning steering wheel slowly when vehicle stopped Steering wheel vibrates and noise occurs when turning steering wheel with vehicle stopped

SP-2

Front suspension (Lower ball joint)

SP-23

Steering gear assembly

PS-73

Power steering motor

SR-30 -

Power source voltage of power steering ECU

IN-26

Power steering ECU

PS-89

Steering center point (zero point) not recorded completely

PS-12

Front tires (improperly inflated, unevenly worn)

TW-1

Front wheel alignment (incorrect)

SP-2

Front suspension (Lower ball joint)

SP-23

Steering gear assembly

PS-73

Torque sensor (built into steering column)

SR-30

Steering column assembly

SR-30

Power steering motor

SR-30

Power steering ECU

PS-89

Front suspension (Lower ball joint)

SP-23

Speed sensor (w/ ABS)

BC-14

Skid control ECU (ABS ECU)

BC-89

Combination meter (w/o ABS)

ME-145

Torque sensor (built into steering column)

SR-30

Power steering motor

SR-30

Power steering ECU

PS-89

Controlling CAN communication system

CA-9

Power steering motor

SR-30

Steering column assembly

SR-30

Power steering motor

SR-30

Power steering motor

SR-30

Steering column assembly

SR-30

Power source voltage of power steering ECU P/S warning always indicated on combination meter

TW-1

Front wheel alignment (incorrect)

Battery and power source system

Steering effort differs between turning right and left or uneven

See page

Combination meter

IN-26 ME-145

Power steering ECU

PS-89

for Sedan Symptom

Heavy steering

Suspected area Front tires (improperly inflated, unevenly worn)

TW-1

Front wheel alignment (incorrect)

SP-2

Front suspension (Lower ball joint)

SP-23

Steering gear assembly

PS-63

Power steering motor

SR-12

Battery and power source system

PS

See page

-

Power source voltage of power steering ECU

IN-26

Power steering ECU

PS-83


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM Symptom

Steering effort differs between turning right and left or uneven

While driving, steering effort does not change in accordance with vehicle speed or steering wheel does not return properly

Friction occurs when turning steering wheel during low speed driving High-pitched sound (squeaking) occurs when turning steering wheel slowly when vehicle stopped Steering wheel vibrates and noise occurs when turning steering wheel with vehicle stopped

Suspected area

See page

Steering center point (zero point) not recorded completely

PS-12

Front tires (improperly inflated, unevenly worn)

TW-1

Front wheel alignment (incorrect)

SP-2

Front suspension (Lower ball joint)

SP-23

Steering gear assembly

PS-63

Torque sensor (built into steering column)

SR-12

Steering column assembly

SR-12

Power steering motor

SR-12

Power steering ECU

PS-83

Front suspension (Lower ball joint)

SP-23

Speed sensor (w/ABS)

BC-14

Skid control ECU (ABS ECU)

BC-89

Combination meter (w/o ABS)

ME-138

Torque sensor (built into steering column)

SR-12

Power steering motor

SR-12

Power steering ECU

PS-83

Controlling CAN communication system

CA-9

Power steering motor

SR-12

Steering column assembly

SR-12

Power steering motor

SR-12

Power steering motor

SR-12

Steering column assembly

SR-12

Power source voltage of power steering ECU P/S warning always indicated on combination meter

PS–23

Combination meter Power steering ECU

IN-26 ME-138 PS-83

PS


PS–24

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

TERMINALS OF ECU Power Steering ECU:

A19

b1

D31

c1 F044303E02

Symbols (Terminals No.)

Terminal Description

Condition

Specified Condition

PIG (A19-1) - PGND (A19-2)

EPS fuse

Always

11 to 14 V

PGND (A19-2) - Body ground

Body ground

Always

Below 1 Ω

M1 (b1-1) - PGND (A19-2)

Power steering motor

1. With ignition switch on, turn steering wheel to left 2. With ignition switch on, turn steering wheel to right

1. 11 to 14 V 2. Below 1 V

M2 (b1-2) - PGND (A19-2)

Power steering motor

1. With ignition switch on, turn steering wheel to left 2. With ignition switch on, turn steering wheel to right

1. Below 1 V 2. 11 to 14 V

CANH (D31-1) - CANL (D31-7)

CAN BUS

Ignition switch off

108 to 132 Ω

DLC3

Communication established by connecting intelligent tester to DLC3

Pulse generation (See waveform 1)

IG (D31-6) - PGND (A19-2)

ECU-IG fuse

Ignition switch on

11 to 14 V

TS (D31-11) - PGND (A19-2)

DLC3

Ignition switch on

11 to 14 V

SPD* (D31-5) - PGND (A19-2)

Speed signal

Ignition switch on

Pulse generation (See waveform 2)

TRQ1 (c1 -5) - PGND (A19-2)

Torque sensor

With ignition switch on, turn steering wheel to left and right

0.3 to 4.7 V

TRQV (c1-6) - PGND (A19-2)

Torque sensor

Ignition switch on

7.5 to 8.5 V

TRQ2 (c1-7) - PGND (A19-2)

Torque sensor

With ignition switch on, turn steering wheel to left and right

0.3 to 4.7 V

TRQG (c1-8) - PGND (A19-2)

Torque sensor

Always

Below 1 Ω

SIL (D31-2) - PGND (A19-2)

* Only for vehicles without ABS 1.

Waveform 1 Reference Terminal

PS

GND

C081996E02

SIL - Body ground

Tool setting

5 V/DIV, 1 ms/DIV

Condition

Communication established by connecting intelligent tester to DLC3


PS–25

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

2.

Waveform 2 Reference Terminal

SPD - Body ground

Tool setting

5 V/DIV, 20 ms/DIV

Condition

Vehicle speed approximately 12.4 mph (20 km/h)

C053421E05

DIAGNOSIS SYSTEM CG SG CANH SIL

CANL

1.

CHECK DLC3 (a) Check the DLC3: The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format.

BAT H100769E16

Symbols (Terminal No.)

Terminal Description

Condition

Specified Condition

SIL (7) - SG (5)

Bus "+" line

During transmission

Pulse generation

CG (4) - Body ground

Chassis ground

Always

Below 1 Ω

SG (5) - Body ground

Signal ground

Always

Below 1 Ω

BAT (16) - Body ground

Battery positive

Always

CANH (6) - CANL (14)

CAN bus line

Ignition switch OFF

CANH (6) - CG (4)

HIGH-level CAN bus line

Ignition switch OFF*

200 Ω or higher

LOW-level CAN bus line

Ignition switch OFF

*

200 Ω or higher

Ignition switch OFF

*

6 kΩ or higher

Ignition switch OFF

*

6 kΩ or higher

CANL (14) - CG (4) CANH (6) - BAT (16) CANL (14) - BAT (16)

HIGH-level CAN bus line LOW-level CAN bus line

11 to 14 V *

54 to 69 Ω

NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the CAN VIM, connect the CAN VIM to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle.

PS


PS–26

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

• If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. 2. P/S Warning light

P/S

WARNING LIGHT (a) When a problem occurs in the electronic power steering system, the P/S warning light on the combination meter comes on to inform the driver of the problem.

F100395E02

for HATCHBACK:

DTC CHECK / CLEAR

Intelligent Tester

1.

DLC3

CHECK DTC (a) When using an intelligent tester;

CAN VIM C115104E14

for SEDAN:

(1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on and turn the tester on. (3) Read the DTCs by following the prompts on the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details.

Intelligent Tester

DLC3 CAN VIM B142272E04

DLC3:

(b) When not using an intelligent tester; (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 (2) Turn the ignition switch on.

CG

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TC

PS

F100115E02


PS–27

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

(3) Read and write down any DTCs indicated by the P/S warning light on the combination meter. Refer to the chart on the left for examples of a normal code and DTCs 21 and 22. HINT: • If the P/S warning light does not blink to display any DTCs set or the normal code, inspect the circuit shown in the table below.

Normal Code: 0.25 0.25 ON OFF

(seconds) Codes 21 and 22: 0.5

ON OFF

2.5

0.5 1.5

0.5

4

2. Code 21

Code 22 (seconds) F040045E02

DLC3:

CG

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TS

F100115E29

Trouble Area

See Page

EPS warning light circuit

PS-53

• If two or more malfunctions are detected simultaneously, DTCs will be displayed in ascending numerical order. (4) Refer to the Diagnostic Trouble Code Chart (See page PS-29 ) for DTC information. CLEAR DTC (a) When using an intelligent tester; (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on and turn the tester on. (3) Clear the DTCs by following the prompts on the intelligent tester. (4) Turn the ignition switch off. (5) Disconnect the intelligent tester from the DLC3. (b) When not using an intelligent tester; (1) Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3. SST 09843-18040 (2) Turn the ignition switch on. (3) Disconnect the SST check wire from terminal 4 (CG) and reconnect it, and repeat this procedure 4 times or more within 8 seconds. (4) Check that the P/S warning light blinks a code to indicate normality. (5) Turn the ignition switch off. (6) Remove the SST from the DLC3.

PS


PS–28

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

FAIL-SAFE CHART When a problem occurs in the electronic power steering system, the P/S warning light on the combination meter comes on, and the ECU stops the steering power assist, maintains the amount of power assist constant, or reduces the amount of power assist to protect the system. DTC No.

Malfunction

Fail-safe

C1511/11 C1512/12 C1513/13 C1514/14

Torque sensor malfunction

Assist force restricted

C1517/17

Torque sensor malfunction

Power assist stopped

C1524/24

Motor malfunction

Power assist stopped

C1531/31 C1532/32

Power steering ECU malfunction

Power assist stopped

C1533/33

Temperature sensor malfunction in power steering ECU

Assist force restricted

C1534/34

EEPROM abnormal

Assist force restricted

C1535/35

Steering wheel location data error

Power assist stopped

C1541/41 C1542/42

Speed sensor malfunction

Amount of power assist remains constant at speed of 43 mph (70 Km/h)

C1551/51

IG power source voltage error

Assist force restricted

C1552/52

PIG power source voltage error

Assist force restricted

C1553/53

Overvoltage at IG and PIG terminals

Assist force restricted

C1554/54

Power source relay malfunction

Power assist stopped

C1555/55

Motor relay malfunction

Power assist stopped

U0073

CAN bus malfunction

-

U0105

ECM communication error

Amount of power assist remains constant at speed of 43 mph (70 Km/h)

U0121

ABS ECU communication error

Amount of power assist remains constant at speed of 43 mph (70 Km/h)

-

Extremely high temperature in ECU

Assist force restricted until normal ECU temperature recovers

-

Power source voltage drop

Assist force suspended until voltage recovers

HINT: The amount of power assist may be decreased to prevent the motor and ECUs from overheating if the steering wheel is continuously turned when the vehicle is either stopped or driven at a low speed, or if the steering wheel is kept at either full lock position for a long time. In such cases, the amount of power assist returns to normal if the steering wheel is not turned for approximately 10 minutes with the engine idling.

PS


PS–29

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DATA LIST / ACTIVE TEST 1.

Item

DATA LIST (a) Connect an intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Operate the intelligent tester according to the prompts on the tester and select DATA LIST.

Item Description

Inspection Condition

Reference value

Torque sensor 1 output value: Minimum: 0 V, Maximum: 5 V

1. Steering wheel not turned (without load) 2. Steering wheel turned to right with vehicle stopped 3. Steering wheel turned to left with vehicle stopped

1. 2.3 to 2.7 V 2. 2.5 to 4.7 V 3. 0.3 to 2.5 V

Torque sensor 2 output value: Minimum: 0 V, Maximum: 5 V

1. Steering wheel not turned (without load) 2. Steering wheel turned to right with vehicle stopped 3. Steering wheel turned to left with vehicle stopped

1. 2.3 to 2.7 V 2. 2.5 to 4.7 V 3. 0.3 to 2.5 V

Torque value for assist control: Minimum: 0 V, Maximum: 5 V

1. Steering wheel not turned (without load) 2. Steering wheel turned to right with vehicle stopped 3. Steering wheel turned to left with vehicle stopped

1. 2.3 to 2.7 V 2. 2.5 to 4.7 V 3. 0.3 to 2.5 V

SPD

Vehicle speed from meter: Minimum: 0 mph (km/h), Maximum: 158.5 mph (255 km/h)

1. Vehicle stopped 2. Vehicle driven at constant speed

1. 0 mph (km/h) 2. No significant fluctuation

MOTOR ACTUAL

Current to motor: Minimum: -128 A, Maximum: 127 A

-

-

COMMAND VALUE

Requested current to motor: Minimum: -128 A, Maximum: 127 A

-

-

THERMISTOR TEMP

ECU substrate temperature: Minimum: -50 °C, Maximum: 205 °C

Ignition switch on

-

PIG SUPPLY

Power source voltage to activate motor: Minimum: 0 V, Maximum: 25.5 V

Power steering in operation

IG SUPPLY

ECU power source voltage: Minimum: 0 V, Maximum: 25.5 V

TRQ1 ZERO VAL

Zero point value of torque sensor 1: Minimum: 0 V, Maximum: 5 V

Steering wheel not turned (without load)

2.3 to 2.7 V

TRQ2 ZERO VAL

Zero point value of torque sensor 2: Minimum: 0 V, Maximum: 5 V

Steering wheel not turned (without load)

2.3 to 2.7 V

TRQ3 ZERO VAL

Zero point value of torque sensor for assist control: Minimum: 0 V, Maximum: 5 V

Steering wheel not turned (without load)

2.3 to 2.7 V

MOTOR TERMINAL(+)

Motor terminal M1 voltage: Minimum: 0 V, Maximum: 25.5 V

1. Steering wheel turned to right 2. Steering wheel turned to left

1. Below 1 V 2. 11 to 14 V

MOTOR TERMINAL(-)

Motor terminal M2 voltage: Minimum: 0 V, Maximum: 25.5 V

1. Steering wheel turned to right 2. Steering wheel turned to left

1. 11 to 14 V 2. Below 1 V

MTR OVERHEAT

Continuous overheat prevention control record: REC/UNREC

-

-

MTR LOW POWER

PIG power source voltage drop record: REC/UNREC

-

-

TRQ1

TRQ2

TRQ3

-

11 to 14 V

11 to 14 V

PS


PS–30

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM Item

Inspection Condition

Reference value

CONTROL MODE

Codes indicating DTC detection timing during ECU control displayed in hexadecimal

-

-

IG ON/OFF TIMES

Number of times ignition switch turned on after DTC detection: Minimum: 0 time, Maximum: 255 times

-

-

# CODE

Number of detected DTCs when freeze frame data stored: Minimum: 0 time, Maximum: 255 times

-

-

ECU ID

ECU identification information

-

-

Selected mode: NORMAL MODE / TEST MODE

-

-

TEST MODE STAT

PS

Item Description


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–31

DIAGNOSTIC TROUBLE CODE CHART HINT: • If any DTCs are displayed during the DTC check, inspect the circuit listed for those DTCs. For details of each DTC, refer to the page indicated in the DTC chart. • Test mode code C1571/71 is stored during the transition to test mode. This code does not indicate a malfunction since the code will be cleared when the ECU determines that the sensor is normal. The test mode code is cleared simultaneously when test mode is terminated. • The P/S warning light remains illuminated during test mode and starts blinking when the speed sensor is determined to be normal. DTC No.

Detection Item

Trouble Areas •

C1511/11

Torque Sensor 1 Malfunction

• •

C1512/12

Torque Sensor Circuit Malfunction

• •

C1513/13

Torque Sensor Circuit Malfunction

• •

C1514/14

Torque Sensor Power Source Circuit Malfunction

• •

C1515/15

Torque Sensor Zero Point Adjustment is not Initialized

• •

C1516/16

Torque Sensor Zero Point Adjustment Incomplete

• •

C1517/17

Torque Sensor Hold Malfunction

• •

Normal Return

P/S Warning Light

See page

Steering column assembly (Torque sensor) Power steering ECU

Ignition switch on again

{

PS-32

Steering column assembly (Torque sensor) Power steering ECU

Ignition switch on again

{

PS-32

Steering column assembly (Torque sensor) Power steeing ECU

Ignition switch on again

{

PS-32

Steering column assembly (Torque sensor) Power steering ECU

Ignition switch on again

{

PS-32

Torque sensor zero point calibration not performed Steering column assembly

After calibrating torque sensor zero point

{

PS-35

Torque sensor zero point calibration failure Steering column assembly

After calibrating torque sensor zero point normally

{

PS-36

Steering column assembly (Torque sensor) Power steering ECU

Ignition switch on again

{

PS-32

Steering column assembly Power steering ECU

Ignition switch on again

{

PS-37

C1524/24

Motor Circuit Malfunction

C1531/31

EPS ECU Circuit Malfunction

Power steering ECU

Ignition switch on again

{

PS-40

C1532/32

EPS ECU Circuit Malfunction

Power steering ECU

Ignition switch on again

{

PS-40

C1533/33

EPS ECU Circuit Malfunction

Power steering ECU

Ignition switch on again

{

PS-40

PS


PS–32

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC No.

Detection Item

Trouble Areas

Normal Return

P/S Warning Light

See page

C1534/34

EPS ECU Circuit Malfunction

Power steering ECU

Ignition switch on again

-

PS-40

C1535/35

Steering Wheel Location Data Error

Power steering ECU

-

{

PS-40

• •

Speed sensor Speed sensor circuit Combination meter Power steering ECU

Ignition switch on again

{

PS-41

Speed sensor Speed sensor circuit Combination meter Power steering ECU

Return to normal

X

PS-41

ECU-IG fuse IG power source circuit Power steering ECU

Ignition switch on again and after normal confirmation

{

PS-44

EPS fuse PIG power source circuit Power steering ECU

Ignition switch on again and after normal confirmation

{

PS-46

IG and PIG power source circuit Power steering ECU

Ignition switch on again and after normal confirmation

{

PS-46

EPS fuse PIG power source circuit Power steering ECU

Ignition switch on again

{

PS-46

Power steering ECU

Ignition switch on again

{

PS-46

• •

Speed sensor Speed sensor circuit Combination meter Power steering ECU

-

-

PS-41

C1541/41 *1

Speed Sensor Malfunction

• • • •

C1542/42 *1

Speed Sensor Malfunction

• •

C1551/51

C1552/52

IG Power Source Circuit Malfunction

PIG Power Source Circuit

• • • • • • •

C1553/53

When Resetting Voltage, Vehicle is Being Driven

• • •

C1554/54

EPS Relay Circuit •

C1555/55

C1571/71 *1

EPS Motor Relay Circuit

Speed Sensor Malfunction (Test Mode DTC)

• •

C1581/81

Assist Map UnWriting

Power steeering ECU

-

{

PS-49

Control Module Communication Bus OFF

U0073

CAN communication system

Ignition switch on again and after normal confirmation

{

PS-50

U0105

Lost Communication with ECM

CAN communication system ECM

Ignition switch on again and after normal confirmation

{

PS-50

U0121 *2

Lost Communication with Anti-lock Brake System (ABS) Control Module

CAN communication system ABS ECU

Ignition switch on again and after notmal confirmation

{

PS-50

PS

(Warning light) {---turn on, X---turn off (Normal reset) *1---w/o ABS, *2---w/ ABS


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC

C1511/11 Torque Sensor 1 Malfunction

DTC

C1512/12 Torque Sensor Circuit Malfunction

DTC

C1513/13 Torque Sensor Circuit Malfunction

DTC

C1514/14

DTC

C1517/17 Torque Sensor Hold Malfunction

PS–33

Torque Sensor Power Source Circuit Malfunction

DESCRIPTION The torque sensor converts the rotation torque input from the steering wheel into electric signals and sends them to the power steering ECU. DTC No.

Detection Item

Trouble Area

C1511/11

Torque sensor (TRQ1) signal error or stop

C1512/12

Torque sensor (TRQ2) signal error or stop

C1513/13

Deviation between torque sensor TRQ1 and TRQ2 exceeds specified value

C1514/14

Torque sensor power source voltage error

C1517/17

Temporary control due to malfunction related to torque sensor continues for long time

Torque sensor (built into steering column assembly) Power steering ECU

WIRING DIAGRAM Power Steering (Torque Sensor)

Power Steering ECU

TRQ 1

TRQ 1

TRQ V

TRQ V

TRQ 2

TRQ 2

TRQ G

(GND)

TRQ G

F044868E02

PS


PS–34

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECTION PROCEDURE

1

READ VALUE OF DATA LIST (TRQ1, TRQ2) (a) (b) (c) (d) Item TRQ1

TRQ2

Connect the intelligent tester to DLC3. Turn the ignition switch on and turn the tester on. Select the items [TRQ1] and [TRQ2] in the DATA LIST. Measure the voltage.

Item Description

Inspection Condition

Torque sensor 1 output value Minimum: 0 V, Maximum: 5 V Torque sensor 2 output value Minimum: 0 V, Maximum: 5 V

1. Steering wheel not turned (without load) 2. Turning steering wheel to right with vehicle stopped 3. Turning steering wheel to left with vehicle stopped

Reference Value

1. 2.3 to 2.7 V 2. 2.5 to 4.7 V 3. 0.3 to 2.5 V

(e) Check the difference in the values between [TRQ1] and [TRQ2]. OK: The voltage difference is below 0.3 V. OK

CHECK INTERMITTENT PROBLEMS

NG

2

INSPECT POWER STEERING ECU (OUTPUT) (a) Turn the ignition switch on. (b) Measure the voltage. Standard voltage

Power Steering ECU:

c1

Tester Connection

Condition

Specified condition

TRQV (c1-6) - TRQG (c1-8)

Ignition switch on

7.5 to 8.5 V

NG TRQG(-)

REPLACE POWER STEERING ECU

TRQV(+) F046432E01

OK

3

INSPECT STEERING COLUMN ASSEMBLY (TORQUE SENSOR)

Power Steering ECU: TRQ1(+) c1

PS TRQG(-)

TRQ2(+)

F046432E02

(a) Turn the ignition switch on. (b) Measure the voltage. Standard voltage Tester Connection

Condition (Steering Position)

Specified Condition

TRQ1 (c1-5) - TRQG (c1-8)

Center position

2.3 to 2.7 V

TRQ2 (c1-7) - TRQG (c1-8)

Center position

2.3 to 2.7 V

TRQ1 (c1-5) - TRQG (c1-8)

Turned to right

2.5 to 4.7 V


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–35

Tester Connection

Condition (Steering Position)

Specified Condition

TRQ2 (c1-7) - TRQG (c1-8)

Turned to right

2.5 to 4.7 V

TRQ1 (c1-5) - TRQG (c1-8)

Turned to left

0.3 to 2.5 V

TRQ2 (c1-7) - TRQG (c1-8)

Turned to left

0.3 to 2.5 V

NG

REPLACE STEERING COLUMN ASSEMBLY

OK REPLACE POWER STEERING ECU

PS


PS–36

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC

C1515/15

Torque Sensor Zero Point Adjustment is not Initialized

DESCRIPTION This DTC does not indicate a malfunction. The power steering ECU outputs this DTC when it determines that the torque sensor zero point calibration has not been performed. DTC No.

DTC Detection Condition

Trouble Area

C1515/15

Torque sensor zero point calibration not performed.

• •

Torque sensor zero point calibration Steering column assembly

INSPECTION PROCEDURE

1

PERFORM ZERO POINT CALIBRATION (TORQUE SENSOR)

NEXT

2

CONFIRM DTC (a) Check for DTCs (See page PS-25 ).

Result DTC still output even after performing torque sensor zero point calibration 3 times.

A

DTC still output even after performing torque sensor zero point calibration once or twice.

B

Normal system code output.

C

HINT: The steering column assembly must be replaced if C1515/15 is still output even after the torque sensor zero point calibration is performed 3 times. B C A REPLACE STEERING COLUMN ASSEMBLY

PS

Go to step 1 END


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC

C1516/16

PS–37

Torque Sensor Zero Point Adjustment Incomplete

DESCRIPTION This DTC does not indicate a malfunction. The power steering ECU outputs this DTC when it determines that the torque sensor zero point calibration has not been completed successfully. DTC No.

DTC Detection Condition

Trouble area

C1516/16

Torque sensor zero point calibration not completed successfully.

• •

Torque sensor zero point calibration failure Steering column assembly

INSPECTION PROCEDURE

1

CLEAR DTC

NEXT

2

PERFORM INITIALIZATION (TORQUE SENSOR ZERO POINT)

NEXT

3

PERFORM ZERO POINT CALIBRATION (TORQUE SENSOR)

NEXT

4

CONFIRM DTC (a) Check for DTCs (See page PS-25 ).

Result DTC still output even after performing torque sensor zero point calibration 3 times.

A

DTC still output even after performing torque sensor zero point calibration once or twice.

B

Normal system code output.

C

HINT: The steering column assembly must be replaced if C1516/16 is still output even after the torque sensor zero point calibration is performed 3 times. B C A REPLACE STEERING COLUMN ASSEMBLY

Go to step 1 END

PS


PS–38

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC

C1524/24 Motor Circuit Malfunction

DESCRIPTION The power steering ECU supplies the current to the power steering motor through the motor circuit. DTC No.

DTC Detection Condition

Trouble Area

C1524/24

Short (or open) in motor circuit or abnormal voltage or current in motor circuit.

• •

Steering column assembly Power steering ECU

WIRING DIAGRAM

Power Steering ECU

M1 Power Steering Motor

M M2

C117915E01

INSPECTION PROCEDURE

1

READ VALUE OF DATA LIST (MOTOR ACTUAL CURRENT) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the items [MOTOR ACTUAL CURRENT] and [COMMAND VALUE] in the DATA LIST and read the value displayed on the intelligent tester.

Standard current Data List Item

Steering Position (Left Turned)

Steering Position (Center)

Steering Position (Right Turned)

MOTOR ACTUAL

10 A to 55 A

-1 A to +1 A

-55 A to -10 A

COMMAND VALUE

55 A

0A

-55 A

HINT: The current changes when steering wheel is turned. OK NG

PS

CHECK INTERMITTENT PROBLEMS


PS–39

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

2

INSPECT POWER STEERING ECU (a) Turn the ignition switch on. (b) Measure the voltage. Standard voltage

Power Steering ECU: M1

PGND A19

b1

M2 F046434E01

Tester Connection

Condition (Steering Position)

Specified Condition

M1 (b1-1) - PGND (A192)

Turned to right

Below 1 V

M1 (b1-1) - PGND (A192)

Turned to left

11 to 14 V

M2 (b1-2) - PGND (A192)

Turned to right

11 to 14 V

M2 (b1-2) - PGND (A192)

Turned to left

Below 1 V

OK

Go to step 4

NG

3

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU - BODY GROUND) (a) Disconnect the connector from the power steering ECU. (b) Measure the resistance and the voltage. Standard

Power Steering ECU:

PIG A19 PGND

F046438E01

Tester Connection

Condition

Specified Condition

PGND (A19-2) - Body ground

Always

Below 1 Ω

PIG (A19-1) - Body ground

Ignition switch on.

11 to 14 V

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

4

INSPECT STEERING COLUMN ASSEMBLY (POWER STEERING MOTOR) (a) Disconnect the connector from the power steering ECU. (b) Measure the resistance. Standard resistance

Power Steering Motor Connector: M1 b1 M2

Tester Connection

Condition

Specified Condition

M1 (b1-1) - M2 (b1-2)

Always

0.08 to 0.15 Ω

M1 (b1-1) - Body ground

Always

1 MΩ or higher

M2 (b1-2) - Body ground

Always

1 MΩ or higher

F046435E01

NG

REPLACE STEERING COLUMN ASSEMBLY

PS


PS–40

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

OK REPLACE POWER STEERING ECU

PS


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC

C1531/31 EPS ECU Circuit Malfunction

DTC

C1532/32 EPS ECU Circuit Malfunction

DTC

C1533/33 EPS ECU Circuit Malfunction

DTC

C1534/34 EPS ECU Circuit Malfunction

DTC

C1535/35 Steering Wheel Location Data Error

PS–41

DESCRIPTION The fail-safe function operates to stop power assist when DTCs indicating ECU malfunctions are output. However, the power assist operation continues when DTC C1534/34 is output because it indicates an EEPROM error in the ECU. DTC No.

DTC Detection Condition

C1531/31

ECU internal malfunction (CPU malfunction)

C1532/32

ECU internal malfunction (Peripheral circuit malfunction)

C1533/33

ECU internal malfunction (Substrate temperature sensor malfunction)

C1534/34

ECU internal malfunction (EEPROM error)

C1535/35

Steering wheel location data error (LHD or RHD)

Trouble Area

Power steering ECU

INSPECTION PROCEDURE

1

CONFIRM DTC (a) Check for DTCs. OK: DTCs other than C1531/31, C1532/32, C1533/33, C1534/34 and C1535/35 are not output. NG

REPAIR CIRCUITS INDICATED BY OUTPUT DTCS

OK REPLACE POWER STEERING ECU

PS


PS–42

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC

C1541/41 Speed Sensor Malfunction

DTC

C1542/42 Speed Sensor Malfunction

DTC

C1571/71 Speed Sensor Malfunction (Test Mode DTC)

DESCRIPTION The power steering ECU controls the assisting power in accordance with the vehicle speed signals from the combination meter. HINT: These DTCs are only for vehicles without a skid control ECU (ABS ECU). When the sensor is normal, a pulse signal (43 Hz at 37 mph [60 km/h]) that alternates between 0 V and 5 V is transmitted to the ECU. DTC No. C1541/41 C1542/42 C1571/71

PS

Detection Item Speed sensor malfunction. Speed sensor malfunction (Test mode).

Trouble Area • • • •

Speed sensor Speed sensor circuit Combination meter Power steering ECU


PS–43

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

WIRING DIAGRAM

Combination Meter

Power Steering ECU

IG1 SPD

4P OUT

ECU-IG

Speed Si CANH

CANL

CANL

CANH Warning signal IG

AM1

PGND

Ignition Switch

ALT

IG1 SI

SE

Battery

Vehicle Speed Sensor (in Automatic Transaxle)

C117902E01

INSPECTION PROCEDURE HINT: Confirm that DTC C1571/71 has been cleared by activating test mode after the repair is completed.

PS


PS–44

1

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

READ VALUE OF DATA LIST (SPD) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the item [SPD] in the DATA LIST and read the value displayed on the intelligent tester. (d) Drive the vehicle and check that there is no significant difference between the speed value displayed by the intelligent tester and the speed value displayed by the speedometer. OK: Speed values are same. HINT: There is tolerance of + - 10 % in the speedometer indication. OK

CHECK INTERMITTENT PROBLEMS

NG

2

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU - COMBINATION METER) (a) Disconnect the connectors from the power steering ECU and the combination meter. (b) Measure the resistance. Standard resistance

Combination Meter (harness side):

                       

D1

Tester Connection

Condition

Specified Condition

SPD (D31-5) - 4P OUT (D1-16)

Always

Below 1 â„Ś

SPD (D31-5) - Body ground

Always

10 kâ„Ś or higher

4P OUT

NG

Power steering ECU:

D31

SPD C122913E01

OK

PS

GO TO COMBINATION METER SYSTEM

REPAIR OR REPLACE HARNESS OR CONNECTOR


PS–45

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC

C1551/51 IG Power Source Circuit Malfunction

DESCRIPTION The power steering ECU distinguishes the ignition switch status as on or off through the IG power source circuit. DTC No.

DTC Detection Condition

Trouble Area

Open or short in IG power source circuit with ignition switch on.

C1551/51

• • •

ECU-IG fuse IG power source circuit Power steering ECU

WIRING DIAGRAM Power Steering ECU

IG1 ECU-IG

IG

AM1 ALT

Ignition Switch

PGND

Battery

C122311E02

INSPECTION PROCEDURE

1

READ VALUE OF DATA LIST (IG SUPPLY) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the item [IG SUPPLY] in the DATA LIST and read the value displayed on the intelligent tester. Standard voltage: 11 to 14 V OK

NG

CHECK INTERMITTENT PROBLEMS

PS


PS–46

2

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECT FUSE (ECU-IG)

Main Body ECU (Instrument Panel Junction Block):

(a) Remove the ECU-IG fuse from the instrument panel J/B. (b) Check the resistance of the fuse. Standard resistance: Below 1 Ω NG

INSPECT SHORT CIRCUIT IN COMPONENTS AND WIRES CONNECTED TO FUSE

ECU-IG fuse C120678E01

OK

3

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU - BODY GROUND) (a) Disconnect the connectors from the power steering ECU. (b) Measure the voltage and the resistance. Standard

Power Steering ECU:

A19 PGND

D31 IG

Tester Connection

Condition

Specified Condition

IG (D31-6) - Body ground

Ignition switch on

11 to 14 V

PGND (A19-2) - Body ground

Always

Below 1 Ω

F046436E01

NG OK REPLACE POWER STEERING ECU

PS

REPAIR OR REPLACE HARNESS OR CONNECTOR


PS–47

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC

C1552/52 PIG Power Source Circuit

DTC

C1553/53

DTC

C1554/54 EPS Relay Circuit

DTC

C1555/55 EPS Motor Relay Circuit

When Resetting Voltage, Vehicle is Being Driven

DESCRIPTION When a problem occurs in the system, the power source relay circuit and the motor relay circuit are shut off to stop the power assist. The ECU must be replaced when there is a problem with the relays because each relay is built into the ECU. DTC No.

DTC Detection Condition

Trouble Area

C1552/52

PIG power source circuit malfunction

• • •

EPS fuse PIG power source circuit Power steering ECU

C1553/53

Abnormal overvoltage

• •

IG and PIG power source circuit Power steering ECU

C1554/54

Power source relay circuit malfunction

• • •

EPS fuse PIG power source circuit Power steering ECU

C1555/55

Motor relay circuit malfunction

Power steering ECU

WIRING DIAGRAM Power Steering ECU ALT

EPS PIG

PGND Battery

C117905E01

INSPECTION PROCEDURE

1

READ VALUE OF DATA LIST (PIG SUPPLY) (a) Connect the intelligent tester to the DLC3. (b) Select the item [PIG SUPPLY] in the DATA LIST and read the value displayed on the intelligent tester.

PS


PS–48

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

Standard voltage: Always 11 to 14 V OK

CHECK INTERMITTENT PROBLEMS

NG

2

INSPECT FUSE (EPS FUSE) (a) Remove the EPS fuse from the engine room R/B. (b) Measure the resistance of the fuse. Standard resistance: Below 1Ω

Engine Room R/B:

NG

INSPECT SHORT CIRCUIT IN COMPONENTS AND WIRES CONNECTED TO FUSE

EPS fuse C117909E01

OK

3

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU - BODY GROUND) (a) Disconnect the connector from the power steering ECU. (b) Measure the voltage and the resistance. Standard

Power Steering ECU:

PIG A19 PGND

OK

PS

F046438E02

Tester Connection

Condition

Specified Condition

PIG (A19-1) - Body ground

Always

11 to 14 V

PGND (A19-2) - Body ground

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

4

PS–49

INSPECT STEERING COLUMN ASSEMBLY (POWER STEERING MOTOR) (a) Disconnect the connector from the power steering ECU. (b) Measure the resistance. Standard resistance

Power Steering Motor Connector: M1 b1 M2

F046435E01

Tester Connection

Condition

Specified Condition

M1 (b1-1) - M2 (b1-2)

Always

0.08 to 0.15 Ω

M1 (b1-1) - Body ground

Always

1 MΩ or higher

M2 (b1-2) - Body ground

Always

1 MΩ or higher

NG

REPLACE STEERING COLUMN ASSEMBLY

OK REPLACE POWER STEERING ECU

PS


PS–50

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC

C1581/81 Assist Map Un-Writing

DESCRIPTION The power steering ECU outputs this DTC when it determines that the assist map is not written in the ECU. The power steering ECU must be replaced when this DTC is output because this malfunction cannot be repaired. HINT: The assist map data is written in the power steering ECU to control assisting power. The assist map is selected from five types based on the vehicle specification communication data (designation and grade package information). DTC No.

DTC Detection Condition

Trouble Area

C1581/81

Assist map not written in power steering ECU

Power steering ECU

INSPECTION PROCEDURE

1

CONFIRM DTC (a) Check for DTCs (See page PS-25 ). OK: DTCs other than C1581/81 are not output. NG

OK REPLACE POWER STEERING ECU

PS

REPAIR CIRCUITS INDICATED BY OUTPUT DTCS


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–51

DTC

U0073

Control Module Communication Bus OFF

DTC

U0105

Lost Communication with ECM

DTC

U0121

Lost Communication with Anti-lock Brake System (ABS) Control Module

DESCRIPTION The power steering ECU receives signals from the ECM and the skid control ECU (ABS ECU) via the CAN communication system. DTC No.

DTC Detection Condition

Trouble Area

U0073

CAN communication error (CAN bus off)

CAN communication system

U0105

ECM communication error

• •

CAN communication system ECM

U0121

Skid control ECU (ABS ECU) communication error

• •

CAN communication system Skid control ECU (ABS ECU)

HINT: When two or more DTCs starting with [U] are output simultaneously, inspect the connectors and wire harness of each ECU.

PS


PS–52

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

WIRING DIAGRAM

Combination Meter

Power Steering ECU

CANL

CANH

CANH

CANL

J/C

J/C

CANH CANL

CANL CANH

ECM

Skid Control ECU

Only for vehicles equipped with ABS

PS

C117903E01


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–53

INSPECTION PROCEDURE

1

CONFIRM DTC (a) Check for DTCs (See page PS-25 ). OK: DTCs other than U0073, U0105 and U0121 are not output. NG

REPAIR CIRCUITS INDICATED BY OUTPUT DTCS

OK GO TO CAN COMMUNICATION SYSTEM

PS


PS–54

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

EPS Warning Light Circuit DESCRIPTION If the power steering ECU detects a malfunction, the P/S warning light comes on. At this time, the power steering ECU stores a DTC in its memory.

PS


PS–55

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

WIRING DIAGRAM

Combination Meter

Power Steering ECU

IG1 ECU-IG

CANH

CANL

CANL

CANH Warning signal IG

AM1

PGND Ignition Switch

ALT

Battery

C120680E04

PS


PS–56

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECTION PROCEDURE

1

INSPECT CAN COMMUNICATION SYSTEM (a) Using the intelligent tester, check for DTCs and confirm that there are no problems in the CAN communication system. OK: DTCs are not output. NG

GO TO CAN COMMUNICATION SYSTEM

OK

2

READ VALUE OF DATA LIST (IG SUPPLY) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the item [IG SUPPLY] in the DATA LIST and read value displayed on the intelligent tester. Standard voltage: 11 to 14 V NG

INSPECT POWER SOURCE CIRCUIT (IG) (See page PS-45)

OK

3

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU - BODY GROUND) (a) Disconnect the connectors from the power steering ECU. (b) Measure the voltage and the resistance. Standard

Power Steering ECU:

A19 PGND

Tester Connection

Condition

Specified Condition

IG (D31-6) - Body ground

Ignition switch on

11 to 14 V

PGND (A19-2) - Body ground

Always

Below 1 Ω

D31 IG F046436E01

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

4

REPLACE POWER STEERING ECU NOTICE: After replacing the power steering ECU, perform the torque sensor zero point calibration.

PS NEXT


POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

5

PS–57

CHECK PS WARNING LIGHT (COMBINATION METER) (a) Check that the P/S warning light on the combination meter does not come on. OK: The P/S warning light does not come on. NG

REPLACE COMBINATION METER

OK END

PS


PS–58

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

TS and CG Terminal Circuit DESCRIPTION The power steering ECU can be changed from normal mode to the mode for the torque sensor zero point calibration by turning the ignition switch on after the DLC3 TS and CG terminals have been connected.

WIRING DIAGRAM DLC3

Power Steering ECU

TS

TS

CG

C117901E01

INSPECTION PROCEDURE

1

INSPECT DLC3 TERMINAL VOLTAGE

DLC3:

(a) Turn the ignition switch on. (b) Measure the voltage. Standard voltage

CG

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TS

NG

PS

OK F100115E29

Tester Connection

Specified Condition

TS (12) - CG (4)

11 to 14 V

END


PS–59

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

2 DLC3:

CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND) (a) Measure the resistance. Standard resistance

CG

1 2 3 4 5 6 7 8

NG

9 10 11 12 13 14 15 16

Tester Connection

Specified Condition

CG (4) - Body ground

Below 1 Ω

REPAIR OR REPLACE HARNESS OR CONNECTOR

F100115E10

OK

3

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU - DLC3) (a) Disconnect the connector from the power steering ECU. (b) Measure the resistance. Standard resistance

DLC3:

Tester Connection

Specified Condition

TS (D31-11) -TS (12)

Below 1 Ω

TS (D31-11) - Body ground

10 kΩ or higher

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

NG TS

REPAIR OR REPLACE HARNESS OR CONNECTOR

Power Steering ECU:

D31 TS C122912E01

OK REPLACE POWER STEERING ECU

PS


POWER STEERING – POWER STEERING GEAR (for Sedan)

PS–59

POWER STEERING GEAR (for Sedan) POWER STEERING STEERING

COMPONENTS

HOOD SUB-ASSEMBLY

13 (133, 10)

N*m (kgf*cm, ft*lbf) : Specified torque

B135922E01

PS


PS–60

POWER STEERING – POWER STEERING GEAR (for Sedan)

FRONT WIPER ARM HEAD CAP FRONT WIPER ARM AND BLADE ASSEMBLY LH

FRONT WIPER ARM AND BLADE ASSEMBLY RH

FRONT WIPER ARM HEAD CAP COWL SIDE VENTILATOR SUB-ASSEMBLY RH

26 (265, 19)

26 (265, 19)

x3

COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

FRONT AIR SHUTTER SEAL

COWL SIDE VENTILATOR SUB-ASSEMBLY LH 5.5 (56, 49 in.*lbf)

x2

FRONT WIPER MOTOR AND LINK

6.5 (66, 58 in.*lbf)

x8

6.5 (66, 58 in.*lbf)

COWL TOP TO COWL INNER BRACE

COWL TOP PANEL OUTER

N*m (kgf*cm, ft*lbf) : Specified torque A133320E05

PS


PS–61

POWER STEERING – POWER STEERING GEAR (for Sedan)

CLIP

COLUMN HOLE COVER SILENCER SHEET

CLIP

74 (755, 55)

STEERING SLIDING YOKE SUB-ASSEMBLY

٨ CLIP 28 (290, 21)

٨ 98 (1,000, 72) ٨ CLIP

74 (755, 55)

٨ 98 (1,000, 72)

FRONT STABILIZER LINK ASSEMBLY RH ٨ COTTER PIN ٨ 49 (500, 36) FRONT STABILIZER LINK ASSEMBLY LH

NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY TIE ROD END SUB-ASSEMBLY RH

٨ COTTER PIN ٨ 49 (500, 36)

95 (969, 70)

TIE ROD END SUB-ASSEMBLY LH FRONT SUSPENSION LOWER ARM RH

70 (714, 52)

for Automatic Transaxle: 160 (1,631, 118)

FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

95 (969, 70)

70 (714, 52) 120 (1,224, 89) 160 (1,631, 118)

FRONT SUSPENSION LOWER ARM LH

120 (1,224, 89)

PS N*m (kgf*cm, ft.*lbf) : Specified torque

٨ Non-reusable part C117208E03


PS–62

POWER STEERING – POWER STEERING GEAR (for Sedan)

96 (979, 71) 96 (979, 71)

POWER STEERING GEAR

NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

PS

N*m (kgf*cm, ft.*lbf) : Specified torque

C119861E02


POWER STEERING – POWER STEERING GEAR (for Sedan)

PS–63

REMOVAL 1.

POSITION FRONT WHEELS FACING STRAIGHT AHEAD

2.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3.

REMOVE HOOD SUB-ASSEMBLY (a) Remove the 4 bolts and remove the hood.

4.

REMOVE FRONT WIPER ARM HEAD CAP (See page WW-9)

5.

REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9)

6.

REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9)

7.

REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (See page WW-10)

8.

REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (See page WW-10)

9.

REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10)

10. REMOVE FRONT WIPER MOTOR AND LINK (See page WW-10) 11. REMOVE FRONT AIR SHUTTER SEAL (See page EM123) 12. REMOVE COWL TOP PANEL OUTER (See page BR41) 13. REMOVE COLUMN HOLE COVER SILENCER SHEET (a) Remove the floor carpet and 2 clips and remove the column hole cover silencer.

A116501

14. REMOVE STEERING SLIDING YOKE SUBASSEMBLY (a) Use a seat belt to fix the steering wheel assembly, in order to avoid breakage of the spiral cable.

PS C139107


PS–64

POWER STEERING – POWER STEERING GEAR (for Sedan)

(b) Place matchmarks on the sliding yoke of the steering intermediate shaft assembly and the power steering. (c) Loosen bolt A, remove bolt B and separate the steering intermediate shaft assembly.

Bolt A Matchmark

Bolt B C118005E03

15. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY (a) Remove clip A, separate clip B from the body and separate No. 1 steering column hole cover subassembly.

Clip B

16. REMOVE FRONT WHEEL Clip A C139112E01

17. REMOVE TIE ROD END SUB-ASSEMBLY LH (See page DS-3) 18. REMOVE TIE ROD END SUB-ASSEMBLY RH HINT: Use the same procedure for the RH side as for the LH side. 19. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (See page DS-4) 20. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure for the RH side as for the LH side. 21. REMOVE FRONT SUSPENSION LOWER ARM LH (See page DS-4) 22. REMOVE FRONT SUSPENSION LOWER ARM RH HINT: Use the same procedure for the RH side as for the LH side. 23. SUSPEND ENGINE ASSEMBLY (a) 1NZ-FE (1) Remove the bolt and remove the radio setting condenser. (2) Remove the bolt and remove the air-fuel ratio sensor wiring bracket.

PS


POWER STEERING – POWER STEERING GEAR (for Sedan)

Front

Rear

A070012E01

PS–65

(3) Install the engine hanger with the bolt in the position shown in the illustration. Part No.: Engine hanger : 12281-21010 Bolt: 91642-81025 Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) (4) Using an engine sling device and a chain block, support the engine assembly w/transaxle and front suspension crossmember. 24. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (a) Remove the bolt and separate the engine moving control rod. (b) Support the front suspension crossmember with a transmission jack.

C107979

(c) Remove the 6 bolts and remove the suspension crossmember.

C107982

25. REMOVE POWER STEERING GEAR (a) Remove the 2 bolts and 2 nuts and remove the power steering gear from the suspension crossmember. NOTICE: Keep the nut from rotating while turning the bolt.

C117189

PS


PS–66

POWER STEERING – POWER STEERING GEAR (for Sedan)

INSTALLATION 1.

INSTALL POWER STEERING GEAR (a) Install the power steering gear onto the front suspension crossmember with the 2 bolts and 2 nuts. Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf) NOTICE: Keep the nut from rotating while turning the bolt.

2.

INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (a) Support the front suspension crossmember with a transmission jack.

C117189

(b) Provisionally install the front suspension crossmember onto the body with the 6 bolts.

Front Bolt A

Bolt A

Bolt B

Bolt B Bolt C

Bolt C A108973E02

PS

Bolt

Underhead Length (mm)

A

38

B

99

C

45

(c) By inserting SST into the datum holes in the front suspension crossmembers RH and LH alternately, tighten bolts A, B and C on both sides to the specified torque, in several steps. SST 09670-00011 Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) for Bolt A 160 N*m (1,631 kgf*cm, 118 ft.*lbf) for Bolt B 95 N*m (969 kgf*cm, 70 ft.*lbf) for Bolt C NOTICE: • Insert SST into the datum hole in a vertical orientation. • If SST can not be inserted into the datum hole vertically, loosen all the bolts and then insert SST again.


PS–67

POWER STEERING – POWER STEERING GEAR (for Sedan) Front

Datum Hole

Bolt A

Bolt A

Bolt B

Bolt B Bolt C

Bolt C

OK

OK

NG

NG A109226E01

(d) Install the engine moving control rod with the bolt. Torque: 120 N*m (1,224 kgf*cm, 89 ft.*lbf) 3.

INSTALL FRONT SUSPENSION LOWER ARM LH (See page DS-14)

4.

INSTALL FRONT SUSPENSION LOWER ARM RH HINT: Use the same procedure for the LH side.

5.

INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-14)

6.

INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure for the LH side.

7.

INSTALL TIE ROD END SUB-ASSEMBLY LH (See page DS-15)

8.

INSTALL TIE ROD END SUB-ASSEMBLY RH HINT: Use the same procedure for the LH side.

9.

INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

C107979E01

PS


PS–68

POWER STEERING – POWER STEERING GEAR (for Sedan)

10. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY (a) Install clip B onto the body portion and install No. 1 steering column hole cover sub-assembly onto the body portion with clip A. NOTICE: Make sure that the lip portion of hole cover No. 1 is not damaged.

Clip B

Clip A C139112E01

11. INSTALL STEERING SLIDING YOKE SUBASSEMBLY (a) Align the matchmarks and install the sliding yoke onto the intermediate shaft. Torque: 28 N*m (290 kgf*cm, 21 ft.*lbf) (b) Tighten bolt A. Torque: 28 N*m (290 kgf*cm, 21 ft.*lbf)

Bolt A Matchmark

Bolt B C118005E03

12. INSTALL COLUMN HOLE COVER SILENCER SHEET (a) Install the column hole cover silencer sheet with the 2 clips. (b) Install the floor carpet. 13. INSTALL COWL TOP PANEL OUTER (See page BR45) 14. INSTALL FRONT AIR SHUTTER SEAL (See page EM148) A116501

15. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See page WW-12) 16. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-12) 17. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (See page WW-13) 18. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (See page WW-13) 19. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-13) 20. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-14) 21. INSTALL FRONT WIPER ARM HEAD CAP (See page WW-15)

PS

22. PROVISIONALLY TIGHTEN HOOD SUB-ASSEMBLY (a) Provisionally install the hood with the 4 bolts. HINT: Tighten the bolts to the specified torque after inspecting the hood. 23. INSPECT HOOD SUB-ASSEMBLY (See page ED-1)


POWER STEERING – POWER STEERING GEAR (for Sedan)

PS–69

24. ADJUST HOOD SUB-ASSEMBLY (See page ED-2) 25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 ft.*lbf) 26. POSITION FRONT WHEELS FACING STRAIGHT AHEAD 27. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page SP-2) 28. CHECK ABS SPEED SENSOR SIGNAL (See page BC-14)

PS


PS–70

POWER STEERING – POWER STEERING GEAR (for Hatchback)

POWER STEERING GEAR (for Hatchback) POWER STEERING STEERING

COMPONENTS

HOOD SUB-ASSEMBLY

13 (133, 9)

13 (133, 9)

N*m (kgf*cm, ft.*lbf) : Specified torque C117202E01

PS


PS–71

POWER STEERING – POWER STEERING GEAR (for Hatchback)

FRONT WIPER ARM HEAD CAP 26 (265, 19)

FRONT WIPER ARM AND BLADE ASSEMBLY RH

CLIP

FRONT WIPER ARM HEAD CAP

FRONT WIPER ARM AND BLADE ASSEMBLY LH

26 (265, 19)

CLIP CLIP COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

COWL TOP VENTILATOR LOUVER LH COWL TOP NO. 1 VENTILATOR LOUVER CENTER HOOD TO COWL TOP SEAL 5.5 (56, 49 in.*lbf) 5.5 (56, 49 in.*lbf)

COWL TO REGISTER DUCT SUB-ASSEMBLY FRONT WIPER MOTOR AND LINK

x9

N*m (kgf*cm, ft*lbf) :Specified torque

6.5 (66, 58 in.*lbf)

COWL TOP PANEL OUTER

PS C116866E11


PS–72

POWER STEERING – POWER STEERING GEAR (for Hatchback)

CLIP

COLUMN HOLE COVER SILENCER SHEET

CLIP

74 (755, 55)

STEERING SLIDING YOKE SUB-ASSEMBLY

٨ CLIP 28 (290, 21)

٨ 98 (1,000, 72) ٨ CLIP

74 (755, 55)

٨ 98 (1,000, 72)

FRONT STABILIZER LINK ASSEMBLY RH ٨ COTTER PIN ٨ 49 (500, 36) FRONT STABILIZER LINK ASSEMBLY LH

NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY TIE ROD END SUB-ASSEMBLY RH

٨ COTTER PIN ٨ 49 (500, 36)

95 (969, 70)

TIE ROD END SUB-ASSEMBLY LH FRONT SUSPENSION LOWER ARM RH

70 (714, 52)

for Automatic Transaxle: 160 (1,631, 118)

FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

95 (969, 70)

70 (714, 52) 120 (1,224, 89) 160 (1,631, 118)

PS

FRONT SUSPENSION LOWER ARM LH

120 (1,224, 89)

N*m (kgf*cm, ft.*lbf) : Specified torque

٨ Non-reusable part C117208E03


POWER STEERING – POWER STEERING GEAR (for Hatchback)

PS–73

96 (979, 71) 96 (979, 71)

POWER STEERING GEAR

NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque C119861E02

PS


PS–74

POWER STEERING – POWER STEERING GEAR (for Hatchback)

REMOVAL 1.

POSITION FRONT WHEELS FACING STRAIGHT AHEAD

2.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3.

REMOVE HOOD SUB-ASSEMBLY (a) Remove the 4 bolts and remove the hood.

4.

REMOVE FRONT WIPER ARM HEAD CAP (See page WW-17)

5.

REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-17)

6.

REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-17)

7.

REMOVE HOOD TO COWL TOP SEAL (See page WW-18)

8.

REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-18)

9.

REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-18)

10. REMOVE WINDSHIELD WIPER MOTOR AND LINK (See page WW-19) 11. REMOVE COWL TO REGISTER DUCT SUBASSEMBLY (See page EM-122) 12. REMOVE COWL TOP PANEL OUTER (See page EM123) 13. REMOVE COLUMN HOLE COVER SILENCER SHEET (a) Remove the floor carpet and 2 clips and remove the column hole cover silencer.

A116501

14. REMOVE STEERING SLIDING YOKE SUBASSEMBLY (a) Use a seat belt to fix the steering wheel assembly, in order to avoid breakage of the spiral cable.

PS C117212


POWER STEERING – POWER STEERING GEAR (for Hatchback)

(b) Place the matchmarks on the sliding yoke of the steering intermediate shaft assembly and the power steering. (c) Loosen bolt A, remove bolt B and separate the steering intermediate shaft assembly

Bolt A Matchmark

PS–75

Bolt B C118005E03

15. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY (a) Remove clip A, separate clip B from the body and separate No. 1 steering column hole cover subassembly. NOTICE: Do not damage clip B.

Clip B

Clip A C118001E01

16. REMOVE FRONT WHEEL 17. REMOVE TIE ROD END SUB-ASSEMBLY (See page DS-3) 18. REMOVE TIE ROD END SUB-ASSEMBLY HINT: Use the same procedure for the RH side as for the LH side. 19. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (See page DS-4) 20. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure for the RH side as for the LH side. 21. REMOVE FRONT SUSPENSION LOWER ARM LH (See page DS-4) 22. REMOVE FRONT SUSPENSION LOWER ARM RH HINT: Use the same procedure for the RH side as for the LH side. 23. SUSPEND ENGINE ASSEMBLY (a) 1NZ-FE (1) Remove the bolt and remove the radio setting condenser. (2) Remove the bolt and remove the air-fuel ratio sensor wiring bracket.

PS


PS–76

POWER STEERING – POWER STEERING GEAR (for Hatchback)

Front

Rear

A070012E01

(3) Install the engine hanger with the bolt in the position shown in the illustration. Part No. : Engine hanger : 12281-21010 Bolt : 91642-81025 Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) (4) Using an engine sling device and chain block, support the engine assembly with transaxle and front suspension crossmember. 24. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (a) Remove the bolt and separate the engine moving control rod. (b) Support the front suspension crossmember with a tool such as a transmission jack.

C107979

(c) Remove the 6 bolts and remove the suspension crossmember.

C107982

25. REMOVE POWER STEERING GEAR (a) Remove the 2 bolts and 2 nuts and remove the power steering gear from the suspension crossmember. NOTICE: Keep the nut from rotating while turning the bolt.

C117189

PS


PS–77

POWER STEERING – POWER STEERING GEAR (for Hatchback)

INSTALLATION 1.

INSTALL POWER STEERING GEAR (a) Install the power steering gear onto the front suspension crossmember with the 2 bolts and 2 nuts. Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf) NOTICE: Keep the nut from rotating while turning the bolt.

2.

INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY SST 09670-00010 (a) Support the front suspension crossmember with a tool such as transmission jack.

C117189

(b) Provisionally install the front suspension crossmember into the vehicle with the 6 bolts

Front Bolt A

Bolt A

Bolt B

Bolt B Bolt C

Bolt C A108973E02

Bolt

Underhead Length (mm)

A

38

B

99

C

45

(c) By inserting SST into the datum holes in the front suspension crossmembers RH and LH sides alternately, tighten bolts A, B and C on both sides to the specified torque, in several steps. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) for Bolt A 160 N*m (1,631 kgf*cm, 118 ft.*lbf) for Bolt B 95 N*m (969 kgf*cm, 70 ft.*lbf) for Bolt C NOTICE: • Insert SST into the datum holes in a vertical orientation. • If SST can not be inserted into the datum holes vertically, loosen all the bolts and then insert SST again.

PS


PS–78

POWER STEERING – POWER STEERING GEAR (for Hatchback) Front

Datum Hole

Bolt A

Bolt A

Bolt B

Bolt B Bolt C

Bolt C

OK

OK

NG

NG A109226E01

(d) Install the engine moving control rod with the bolt. Torque: 120 N*m (1224 kgf*cm, 89 ft.*lbf) 3.

INSTALL FRONT SUSPENSION LOWER ARM LH (See page DS-14)

4.

INSTALL FRONT SUSPENSION LOWER ARM RH HINT: Use the same procedure for the LH side.

5.

INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page DS-4)

6.

INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure for the LH side.

7.

INSTALL TIE ROD END SUB-ASSEMBLY LH (See page DS-15)

8.

INSTALL TIE ROD END SUB-ASSEMBLY RH HINT: Use the same procedure for the LH side.

9.

INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

C107979J01

PS


POWER STEERING – POWER STEERING GEAR (for Hatchback)

PS–79

10. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY (a) Install clip B onto the body portion and install No. 1 steering column hole cover sub-assembly onto the body portion with clip A. NOTICE: Make sure that the lip portion of No. 1 steering column hole cover sub-assembly is not damaged.

Clip B

Clip A C118001E01

11. INSTALL STEERING SLIDING YOKE SUBASSEMBLY (a) Align the matchmarks and install the sliding yoke onto the intermediate shaft. Torque: 28 N*m (290 kgf*cm, 21 ft.*lbf) (b) Tighten bolt A. Torque: 28 N*m (290 kgf*cm, 21 ft.*lbf)

Bolt A Matchmark

Bolt B C118005E03

12. INSTALL COLUMN HOLE COVER SILENCER SHEET (a) Install the column hole cover silencer sheet with the 2 clips. (b) Install the floor carpet 13. INSTALL COWL TOP PANEL OUTER (See page EM146) 14. INSTALL COWL TO REGISTER DUCT SUBASSEMBLY (See page EM-147) A116501

15. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See page WW-21) 16. INSTALL COWL TOP VENTILATOR LOUVER LH (See page WW-21) 17. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-21) 18. INSTALL HOOD TO COWL TOP SEAL (See page WW22) 19. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-17) 20. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-23) 21. INSTALL FRONT WIPER ARM HEAD CAP (See page WW-23) 22. TEMPORARILY TIGHTEN HOOD SUB-ASSEMBLY (a) Provisionally install the hood with the 4 bolts. HINT: Tighten the bolts to the specified torque after inspecting the hood. 23. INSPECT HOOD SUB-ASSEMBLY (See page ED-3)

PS


PS–80

POWER STEERING – POWER STEERING GEAR (for Hatchback)

24. ADJUST HOOD SUB-ASSEMBLY (See page ED-4) 25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 26. POSITION FRONT WHEELS FACING STRAIGHT AHEAD 27. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page SP-2) 28. CHECK ABS SPEED SENSOR SIGNAL (See page BC-14)

PS


POWER STEERING – POWER STEERING ECU (for Sedan)

PS–81

POWER STEERING ECU (for Sedan) POWER STEERING STEERING

COMPONENTS

COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL

INSTRUMENT PANEL FINISH PANEL END RH INSTRUMENT PANEL FINISH PANEL END LH

INSTRUMENT PANEL FINISH PANEL LOWER CENTER

PS E116817E01


PS–82

POWER STEERING – POWER STEERING ECU (for Sedan)

w/ Curtain Shield Airbag:

SPECIAL CLIP

SPECIAL CLIP

FRONT PILLAR GARNISH LH

FRONT PILLAR GARNISH LH

FRONT PILLAR GARNISH RH

FRONT PILLAR GARNISH RH

FRONT DOOR OPENING TRIM WEATHERSTRIP RH FRONT DOOR OPENING TRIM WEATHERSTRIP LH <B>

<B>

<C>

20 (204, 15)

<C> UPPER INSTRUMENT PANEL SUB-ASSEMBLY

GLOVE COMPARTMENT DOOR ASSEMBLY

PS

N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part B132310E02


POWER STEERING – POWER STEERING ECU (for Sedan)

PS–83

POWER STEERING ECU

5.0 (51, 44 in.*lbf)

N*m (kgf*cm, ft.*lbf) : Specified torque C139091E01

PS


PS–84

POWER STEERING – POWER STEERING ECU (for Sedan)

REMOVAL HINT: Use the same procedure for both the RH and LH sides. 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working.

2.

REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page ME-138)

3.

REMOVE INSTRUMENT PANEL FINISH PANEL END LH (See page ME-138)

4.

REMOVE INSTRUMENT PANEL FINISH PANEL END RH (See page ME-138)

5.

REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page ME-139)

6.

REMOVE COMBINATION METER ASSEMBLY (See page ME-139)

7.

SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (a) Separate the front door opening trim weatherstrip.

8.

SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (a) Separate the front door opening trim weatherstrip.

9.

REMOVE FRONT PILLAR GARNISH RH (See page IR18)

10. REMOVE FRONT PILLAR GARNISH LH (See page IR19) 11. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-6) 12. REMOVE UPPER INSTRUMENT PANEL SUBASSEMBLY (See page IP-6) 13. REMOVE POWER STEERING ECU (a) Separate the wire harness clamp.

C117191

PS


POWER STEERING – POWER STEERING ECU (for Sedan)

PS–85

(b) Disconnect the 4 connectors.

C117190

(c) Remove the 2 nuts and remove the power steering ECU.

C118008

INSTALLATION 1.

INSTALL POWER STEERING ECU (a) Install the power steering ECU with the 2 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

PS C118008


PS–86

POWER STEERING – POWER STEERING ECU (for Sedan)

(b) Connect the 4 connectors.

C117190

(c) Install the wire harness clamp. NOTICE: Make sure that the wire harness of the steering column assembly is installed onto the power steering ECU bracket and that it is not pulled too tightly.

C117191

2.

INSTALL UPPER INSTRUMENT PANEL SUBASSEMBLY (See page IP-11)

3.

INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-13)

4.

INSTALL FRONT PILLAR GARNISH RH (See page IR29)

5.

INSTALL FRONT PILLAR GARNISH LH (See page IR30)

6.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-34)

7.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See page IP-14)

8.

INSTALL COMBINATION METER ASSEMBLY (See page ME-140)

9.

INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page ME-140)

10. INSTALL INSTRUMENT PANEL FINISH PANEL END RH (See page ME-141) 11. INSTALL INSTRUMENT PANEL FINISH PANEL END LH (See page ME-141) 12. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page ME-142) 13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

PS

14. CHECK SRS WARNING LIGHT (See page RS-31) 15. PERFORM ZERO POINT CALIBRATION (See page PS-12)


POWER STEERING – POWER STEERING ECU (for Hatchback)

PS–87

POWER STEERING ECU (for Hatchback) POWER STEERING STEERING

COMPONENTS

COMBINATION METER ASSEMBLY

INSTRUMENT CLUSTER FINISH PANEL

INSTRUMENT PANEL FINISH PANEL END RH

INSTRUMENT PANEL FINISH PANEL END LH

PS E107796E02


PS–88

POWER STEERING – POWER STEERING ECU (for Hatchback)

w/ Curtain Shield Airbag: ٨ CLIP ٨ CLIP CLIP

CLIP

٨ FRONT PILLAR GARNISH LH

٨ FRONT PILLAR GARNISH RH

FRONT PILLAR GARNISH RH

FRONT PILLAR GARNISH LH

FRONT DOOR OPENING TRIM WEATHERSTRIP RH

FRONT DOOR OPENING TRIM WEATHERSTRIP LH

UPPER INSTRUMENT PANEL SUB-ASSEMBLY

20 (204, 15)

NO. 1 SWITCH HOLE BASE

PS N*m (kgf*cm, ft.*lbf) : Specified torque

٨ Non-reusable part C119857E02


POWER STEERING – POWER STEERING ECU (for Hatchback)

PS–89

POWER STEERING ECU

5.0 (51, 44 in.*lbf)

N*m (kgf*cm, ft.*lbf) : Specified torque C119079E01

PS


PS–90

POWER STEERING – POWER STEERING ECU (for Hatchback)

REMOVAL 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2.

REMOVE INSTRUMENT PANEL FINISH PANEL END LH (See page ME-145)

3.

REMOVE INSTRUMENT PANEL FINISH PANEL END RH (See page ME-145)

4.

REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page ME-145)

5.

REMOVE COMBINATION METER ASSEMBLY (See page ME-146)

6.

REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-50)

7.

REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH HINT: Use the same procedure for the RH side as for the LH side.

8.

REMOVE FRONT PILLAR GARNISH RH (See page IR58)

9.

REMOVE FRONT PILLAR GARNISH LH (See page IR59)

10. REMOVE NO. 1 SWITCH HOLE BASE (See page IP20) 11. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-20) 12. REMOVE UPPER INSTRUMENT PANEL SUBASSEMBLY (See page IP-21) 13. REMOVE POWER STEERING ECU (a) Separate the wire harness clamp.

C117191

PS


POWER STEERING – POWER STEERING ECU (for Hatchback)

PS–91

(b) Disconnect the 4 connectors.

C117190

(c) Remove the 2 nuts and remove the power steering ECU.

C118008

INSTALLATION 1.

INSTALL POWER STEERING ECU (a) Install the power steering ECU with the 2 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

PS C118008


PS–92

POWER STEERING – POWER STEERING ECU (for Hatchback)

(b) Connect the 4 connectors.

C117190

(c) Install the wire harness clamp. NOTICE: Make sure that the wire harness of the steering column assembly is installed onto the power steering ECU bracket and that it is not pulled too tightly.

C117191

2.

INSTALL UPPER INSTRUMENT PANEL SUBASSEMBLY (See page IP-29)

3.

INSTALL NO. 1 SWITCH HOLE BASE (See page IP32)

4.

INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-32)

5.

INSTALL FRONT PILLAR GARNISH RH (See page IR71)

6.

INSTALL FRONT PILLAR GARNISH LH (See page IR72)

7.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page IR-81)

8.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH HINT: Use the same procedure for the RH side as for the LH side.

9.

INSTALL COMBINATION METER ASSEMBLY (See page ME-148)

10. INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page ME-148) 11. INSTALL INSTRUMENT PANEL FINISH PANEL END RH (See page ME-149) 12. INSTALL INSTRUMENT PANEL FINISH PANEL END LH (See page IR-72)

PS

13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 14. PERFORM CALIBRATION OF TORQUE SENSOR ZERO POINT (See page PS-12).


PREPARATION – 1NZ-FE ENGINE CONTROL SYSTEM

PP–1

1NZ-FE ENGINE CONTROL SYSTEM PREPARATION

SST 09817-33190

Sensor Socket Wrench

PP


PP–2

PREPARATION – 1NZ-FE ENGINE CONTROL SYSTEM

RECOMMENDED TOOLS 09082-00040

(09083-00150)

PP

TOYOTA Electrical Tester

Test Lead Set


PREPARATION – 1NZ-FE ENGINE CONTROL SYSTEM

PP–3

EQUIPMENT Torque wrench Ohmmeter Heater Thermometer

PP


PP–2

PREPARATION – 1NZ-FE ENGINE MECHANICAL

1NZ-FE ENGINE MECHANICAL PREPARATION

SST

PP

09011-38121

12 mm Socket Wrench for 12 Pointed Head

09023-38400

Union Nut Wrench 14mm

09032-00100

Oil Pan Seal Cutter

09201-10000

Valve Guide Bushing Remover & Replacer Set

(09201-01050)

Valve Guide Bushing Remover & Replacer 5

09201-41020

Valve Stem Oil Seal Replacer

09202-70020

Valve Spring Compressor

(09202-00010)

Attachment

09205-16010

Cylinder Head Bolt Wrench

09213-14010

Crankshaft Pulley Holding Tool

(91651-60865)

Bolt


PREPARATION – 1NZ-FE ENGINE MECHANICAL 09221-25026

(09221-00021)

PP–3

Piston Pin Remover & Replacer

Body

PP (09221-00030)

Spring

(09221-00141)

Guide H

(09221-00150)

Bushing D

(09221-00190)

Guide K

09223-56010

Crankshaft Rear Oil Seal Replacer

09228-06501

Oil Filter Wrench

09330-00021

Companion Flange Holding Tool

09670-00010

Front Crossmember Guide Tool

09817-33190

Sensor Socket Wrench

09843-18040

Diagnosis Check Wire No.2


PP–4

PREPARATION – 1NZ-FE ENGINE MECHANICAL 09950-60010

Replacer Set

(09951-00250)

Replacer 25

(09951-00380)

Replacer 38

(09952-06010)

Adapter

PP

09950-70010

Handle Set

(09951-07100)

Handle 100

09960-10010

Variable Pin Wrench Set

(09962-01000)

Variable Pin Wrench Arm Assembly

(09963-00700)

Pin 7

(09963-01000)

Pin 10


PREPARATION – 1NZ-FE ENGINE MECHANICAL

PP–5

RECOMMENDED TOOLS 09011-12301

Socket Wrench 30 mm

09040-00011

Hexagon Wrench Set

PP (09043-20080)

Socket Hexagon Wrench 8

(09043-20100)

Socket Hexagon Wrench 10

09216-00021

Belt Tension Gauge


PPâ&#x20AC;&#x201C;6

EQUIPMENT Alignment tester Angle gauge Bar Caliper gauge CO/HC meter

PP

Compression gauge Connecting rod aligner Cylinder gauge Dial indicator Feeler gauge Heater Micrometer Piston ring compressor Piston ring expander Plastic hammer Plastigage Straight edge Reamer Slide caliper Tachometer Timing light Torque wrench Valve seat cutter V-block Vernier caliper Wooden block Thermometer Spring tester Engine lifter Engine sling device Chain block Wire brush Chisel Hammer Radiator cap tester

PREPARATION â&#x20AC;&#x201C; 1NZ-FE ENGINE MECHANICAL


PREPARATION – 1NZ-FE ENGINE MECHANICAL

PP–7

SSM 08826-00080

Seal Packing Black or equivalent (FIPG)

08826-00100

Seal Packing 1282B, THREE BOND 1282B or equivalent (FIPG)

08833-00070

Adhesive 1324, THREE BOND 1324 or equivalent

PP


PREPARATION – 1NZ-FE FUEL

PP–7

1NZ-FE FUEL PREPARATION

SST 09268-41047

Injection Measuring Tool Set

(09268-41500)

Fuel Tube Connector

(90467-13001)

Clip

(95336-08070)

Hose

09268-41048

Injection Measuring Tool Set

(09268-41110)

Adaptor

(09268-41310)

Clamp

(09268-41500)

Fuel Tube Connector

(90467-13001)

Clip

(95336-08070)

Hose

09268-45014

EFI Fuel Pressure Gauge

PP


PP–8

PREPARATION – 1NZ-FE FUEL (09268-41200)

Gauge

(09268-41220)

Hose

(09268-41250)

T Joint

PP

09808-14020

Retainer Tool,Fuel Pump

(09808-01410)

Holder

(09808-01420)

Claw

(09808-01430)

Bolt

09842-30080

Wire H EFI Inspection


PREPARATION – 1NZ-FE FUEL

PP–9

RECOMMENDED TOOLS 09082-00040

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set

PP


PP–10

EQUIPMENT Stop watch Measuring flask Ohmmeter Torque wrench

PP

PREPARATION – 1NZ-FE FUEL


PREPARATION – 1NZ-FE FUEL

PP–11

SSM 08826-00080

Seal Packing Black or equivalent (FIPG)

PP


PP–10

PREPARATION – 1NZ-FE EMISSION CONTROL

1NZ-FE EMISSION CONTROL PREPARATION

SST 09224-00010

PP

O2 Sensor Wrench


PREPARATION – 1NZ-FE EMISSION CONTROL

PP–11

RECOMMENDED TOOLS 09082-00040

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set

PP


PP–12

EQUIPMENT Ohmmeter Torque wrench Service wire harness

PP

PREPARATION – 1NZ-FE EMISSION CONTROL


PREPARATION – 1NZ-FE EXHAUST

PP–11

1NZ-FE EXHAUST PREPARATION

EQUIPMENT Torque wrench Vernier calipers Wooden block

PP


PP–12

PREPARATION – 1NZ-FE COOLING

1NZ-FE COOLING PREPARATION

SST 09960-10010

PP

Variable Pin Wrench Set

(09962-01000)

Variable Pin Wrench Arm Assembly

(09963-00700)

Pin 7


PREPARATION – 1NZ-FE COOLING

PP–13

EQUIPMENT Heater Slide caliper Thermometer Torque wrench Ohmmeter Radiator cap tester Ammeter Protective tape

PP


PPâ&#x20AC;&#x201C;14

PREPARATION â&#x20AC;&#x201C; 1NZ-FE COOLING

COOLANT Item

Capacity M/T 4.8 liters (5.1 USqts, 4.5 lmp. qts) 4.7 liters (5.0 USqts, 4.4 lmp. qts)

Engine Coolant

PP

A/T

Classification Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).


PREPARATION – 1NZ-FE LUBRICATION

PP–13

1NZ-FE LUBRICATION PREPARATION

SST 09213-14010

(91651-60865)

Crankshaft Pulley Holding Tool

Bolt

09228-06501

Oil Filter Wrench

09330-00021

Companion Flange Holding Tool

09950-60010

Replacer Set

(09951-00250)

Replacer 25

(09951-00410)

Replacer 41

(09952-06010)

Adapter

09950-70010

Handle Set

(09951-07100)

Handle 100

PP


PP–14

EQUIPMENT Deep socket wrench 24 mm Oil pressure gauge Torque wrench Wooden block Feeler gauge

PP

PREPARATION – 1NZ-FE LUBRICATION


PP–15

PREPARATION – 1NZ-FE LUBRICATION

LUBRICANT Item

Capacity

With oil filter change

3.7 liters (3.9 US qts, 3.4 lmp. qts)

Without oil filter change

3.4 liters (3.6 US qts, 3.1 lmp. qts)

Dry fill

4.1 liters (4.3 US qts, 3.8 lmp. qts)

PP


PP–16

PREPARATION – 1NZ-FE LUBRICATION

SSM 08826-00080

Seal Packing Black or equivalent (FIPG)

08826-00100

Seal Packing 1282B, THREE BOND 1282B or equivalent (FIPG)

08833-00070

Adhesive 1324, THREE BOND 1324 or equivalent

PP


PREPARATION – 1NZ-FE IGNITION

PP–15

1NZ-FE IGNITION PREPARATION

RECOMMENDED TOOLS 09082-00040

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set

PP


PP–16

EQUIPMENT Torque wrench Ohmmeter Spark plug cleaner

PP

PREPARATION – 1NZ-FE IGNITION


PP–16

PREPARATION – 1NZ-FE STARTING

1NZ-FE STARTING PREPARATION

RECOMMENDED TOOLS 09082-00040

PP

TOYOTA ElectricalTester

(09083-00150)

Test Lead Set

09904-00010

Expander Set

for 1.6kw Type


PREPARATION – 1NZ-FE STARTING

PP–17

EQUIPMENT for 0.8 kW Type Torque wrench Ammeter (A) Ohmmeter Service wire harness V-block Dial indicator Vernier calipers Vise Sand paper (No.400) Plastic hammer

for 1.6 kW Type Torque wrench Ammeter (A) Ohmmeter Service wire harness Vernier calipers Vise Sand paper (No.400)

PP


PREPARATION – 1NZ-FE CHARGING

PP–17

1NZ-FE CHARGING PREPARATION

SST 09286-46011

Injection Pump Spline Shaft Puller

09820-63010

Alternator Pulley Set Nut Wrench Set

(09820-06010)

Alternator Rotor Shaft Wrench

(09820-06020)

Alternator Pulley Set Nut 22 mm Wrench

PP


PP–18

PREPARATION – 1NZ-FE CHARGING

RECOMMENDED TOOLS 09082-00040

(09083-00150)

PP

TOYOTA Electrical Tester

Test Lead Set


PREPARATION – 1NZ-FE CHARGING

PP–19

EQUIPMENT Torque wrench Ammeter (A) Ohmmeter Volt meter Service wire harness Vernier caliper Vise

PP


PP–18

PREPARATION – U340E AUTOMATIC TRANSAXLE

U340E AUTOMATIC TRANSAXLE PREPARATION

SST

PP

09023-12701

Union Nut Wrench 17mm

09221-25026

Piston Pin Remover & Replacer

(09221-00071)

Guide A

09223-15030

Oil Seal & Bearing Replacer

09308-00010

Oil Seal Puller

09308-10010

Oil Seal Puller

09320-89010

Transfer Clutch Spring Compressor

09350-32014

TOYOTA Automatic Transmission Tool Set

(09351-32010)

One-way Clutch Test Tool

(09351-32020)

Stator Stopper

09350-36010

TOYOTA Automatic Transmission Tool Set


PREPARATION – U340E AUTOMATIC TRANSAXLE (09350-06110)

No.1 Measure Terminal

09387-00020

Direct Clutch Wrench

PP–19

PP 09387-00041

Bearing Puller Assembly

(09387-01021)

Claw No.2

(09387-02010)

Oil Seal Replacer

(09387-02020)

One-way Clutch Test Tool Set

09387-00060

Second Brake Wrench

09387-00070

First & Reverse Brake Wrench

09387-00120

Counter Drive Gear Nut Wrench

09527-17011

Rear Axle Shaft Bearing Remover

09554-14010

Differential Oil Seal Replacer

09612-65014

Steering Worm Bearing Puller


PP–20

PREPARATION – U340E AUTOMATIC TRANSAXLE (09612-01010)

Claw A

(09612-01040)

Claw D

PP 09710-20011

(09710-06071)

09726-27012

(09726-02041)

Front Suspension Bushing Tool Set

Replacer

Front Suspension Arm Bushing Remover & Replacer

Replacer

09726-40010

Lower Control Shaft Bearing Replacer

09930-00010

Drive Shaft Nut Chisel

09950-40011

Puller B Set

(09951-04010)

Hanger 150

(09952-04010)

Slide Arm

(09953-04020)

Center Bolt 150


PREPARATION – U340E AUTOMATIC TRANSAXLE (09953-04030)

Center Bolt 200

(09954-04010)

Arm 25

PP–21

PP (09955-04061)

Claw No.6

(09957-04010)

Attachment

(09958-04011)

Holder

09950-60010

Replacer Set

(09951-00190)

Replacer 19

(09951-00220)

Replacer 22

(09951-00320)

Replacer 32

(09951-00350)

Replacer 35

(09951-00390)

Replacer 39

(09951-00400)

Replacer 40


PP–22

PREPARATION – U340E AUTOMATIC TRANSAXLE (09951-00430)

Replacer 43

(09951-00460)

Replacer 46

(09951-00480)

Replacer 48

(09951-00530)

Replacer 53

(09951-00550)

Replacer 55

(09951-00610)

Replacer 61

(09951-00650)

Replacer 65

(09952-06010)

Adapter

PP

09950-60020

Replacer Set No.2

(09951-00680)

Replacer 68

(09951-00720)

Replacer 72

(09951-00790)

Replacer 79


PREPARATION – U340E AUTOMATIC TRANSAXLE (09951-00890)

Replacer 89

09950-70010

Handle Set

PP–23

PP (09951-07100)

Handle 100

(09951-07150)

Handle 150

(09951-07200)

Handle 200


PP–24

PREPARATION – U340E AUTOMATIC TRANSAXLE

RECOMMENDED TOOLS 09025-00010

Torque Wrench (30 kgf-cm)

09031-00030

Pin Punch

09031-00040

Pin Punch .

09042-00010

Torx Socket T30

09082-00040

TOYOTA Electrical Tester

PP

(09083-00150)

Test Lead Set

09090-04020

Engine Sling Device

09905-00012

Snap Ring No.1 Expander


PREPARATION – U340E AUTOMATIC TRANSAXLE

PP–25

EQUIPMENT Dial indicator with magnetic base Feeler gauge Vernier calipers Torque wrench Plastic hammer Straight edge

PP


PP–26

PREPARATION – U340E AUTOMATIC TRANSAXLE

LUBRICANT

PP

Item

Capacity

Classification

Automatic transaxle fluid (Drain and refill)

2.9 liters (3.1 US qts, 2.6 lmp. qts)

Toyota Genuine ATF WS


PREPARATION – U340E AUTOMATIC TRANSAXLE

PP–27

SSM Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

PP


PREPARATION – CLUTCH

PP–25

CLUTCH PREPARATION

SST 09023-00101

Union Nut Wrench 10 mm

09301-00110

Clutch Guide Tool

09333-00013

Universal Joint Bearing Remover & Replacer

PP


PP–26

EQUIPMENT Torque wrench Vernier calipers Dial gauge Dial indicator

PP

PREPARATION – CLUTCH


PP–27

PREPARATION – CLUTCH

LUBRICANT Item

Capacity

Classification

Brake fluid

-

SAE J1703 or FMVSS No. 116 DOT 3

PP


PP–26

PREPARATION – C50 MANUAL TRANSAXLE

C50 MANUAL TRANSAXLE PREPARATION

SST

PP

09308-00010

Oil Seal Puller

09309-12020

5th Driven Gear Replacer

09309-36010

Transmission Rear Bearing Replacer

09309-37010

Transmission Bearing Replacer

09316-60011

Transmission & Transfer Bearing Replacer

(09316-00011)

Replacer Pipe

(09316-00021)

Replacer A

(09316-00031)

Replacer B

09350-32014

TOYOTA Automatic Transmission Tool Set

(09351-32120)

Overdrive Bearing Replacer

09564-32011

Differential Preload Adaptor


PREPARATION – C50 MANUAL TRANSAXLE 09608-04031

Front Hub Inner Bearing Cone Replacer

09612-22011

Tilt Handle Bearing Replacer

PP–27

PP 09612-65014

Steering Worm Bearing Puller

(09612-01040)

Claw D

(09612-01050)

Hanger Pin with Nut

(09612-01060)

Claw E

09636-20010

Upper Ball Joint Dust Cover Replacer

09710-20011

Front Suspension Bushing Tool Set

(09710-06071)

09710-26011

(09710-05061)

09817-16011

Replacer

Front Suspension Bushing Tool Set

Replacer

Back-up Light Switch Tool


PP–28

PREPARATION – C50 MANUAL TRANSAXLE 09950-00020

Bearing Remover

09950-00030

Bearing Remover Attachment

09950-30012

Puller A Set

(09951-03010)

Upper Plate

(09953-03010)

Center Bolt

(09954-03010)

Arm

(09955-03021)

Claw No.2

PP

09950-40011

Puller B Set

(09951-04010)

Hanger 150

(09951-04020)

Hanger 200

(09952-04010)

Slide Arm

(09953-04020)

Center Bolt 150


PREPARATION – C50 MANUAL TRANSAXLE (09953-04030)

Center Bolt 200

(09954-04010)

Arm 25

PP–29

PP (09955-04011)

Claw No.1

(09955-04061)

Claw No.6

(09957-04010)

Attachment

(09958-04011)

Holder

09950-60010

Replacer Set

(09951-00180)

Replacer 18

(09951-00220)

Replacer 22

(09951-00240)

Replacer 24

(09951-00280)

Replacer 28

(09951-00360)

Replacer 36


PP–30

PREPARATION – C50 MANUAL TRANSAXLE (09951-00370)

Replacer 37

(09951-00420)

Replacer 42

(09951-00530)

Replacer 53

(09951-00550)

Replacer 55

PP

09950-60020

Replacer Set No.2

(09951-00680)

Replacer 68

(09951-00710)

Replacer 71

09950-70010

Handle Set

(09951-07100)

Handle 100

(09951-07150)

Handle 150

(09951-07200)

Handle 200


PREPARATION – C50 MANUAL TRANSAXLE

PP–31

RECOMMENDED TOOLS 09031-00030

Pin Punch

09031-00040

Pin Punch .

PP 09905-00012

Snap Ring No.1 Expander


PP–32

EQUIPMENT Dial indicator Feeler gauge Micrometer Vernier calipers Caliper gauge

PP

Cylinder gauge Torque wrench Dial gauge Chisel Heater

PREPARATION – C50 MANUAL TRANSAXLE


PREPARATION – C50 MANUAL TRANSAXLE

PP–33

LUBRICANT Item

Capacity

Classification

Manual transaxle oil

1.9 liters (2.0 US qts, 1.7 lmp. qts)

API GL-4 SAE 75W

PP


PP–34

PREPARATION – C50 MANUAL TRANSAXLE

SSM

PP

08826-00090

Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG)

08833-00080

Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent


PP–32

PREPARATION – DRIVE SHAFT

DRIVE SHAFT PREPARATION

SST

PP

09520-01010

Drive Shaft Remover Attachment

09520-24010

Differential Side Gear Shaft Puller

(09520-32040)

Shocker Set

09527-10011

Rear Axle Shaft Bearing Remover

09608-16042

Front Hub Bearing Adjusting Tool

(09608-02021)

Bolt & Nut

(09608-02041)

Retainer

09628-00011

Ball Joint Puller

09628-62011

Boll Joint Puller

09930-00010

Drive Shaft Nut Chisel

09950-00020

Bearing Remover


PREPARATION – DRIVE SHAFT

PP–33

RECOMMENDED TOOLS 09011-12301

Socket Wrench 30 mm

09040-00011

Hexagon Wrench Set

PP (09043-20060)

Socket Hexagon Wrench 6

09130-00150

Water Pump Pliers

09905-00012

Snap Ring No.1 Expander


PP–34

EQUIPMENT Torque wrench

PP

PREPARATION – DRIVE SHAFT


PP–35

PREPARATION – DRIVE SHAFT

LUBRICANT Item

Capacity

Front drive shaft outboard joint grease

125 to 135 g (4.4 to 4.8 oz.)

Front drive shaft inboard joint grease

125 to 135 g (4.4 to 4.8 oz.)

PP


PP–34

PREPARATION – AXLE

AXLE PREPARATION

SST

PP

09223-15020

Oil Seal & Bearing Replacer

09223-56010

Crankshaft Rear Oil Seal Replacer

09387-00041

Bearing Puller Assembly

(09387-02010)

Oil Seal Replacer

09520-00031

Rear Axle Shaft Puller

09608-32010

Steering Knuckle Oil Seal Replacer

09628-10011

Ball Joint Puller

09950-40011

Puller B Set

(09951-04020)

Hanger 200

(09952-04010)

Slide Arm

(09953-04020)

Center Bolt 150


PREPARATION – AXLE (09954-04010)

Arm 25

(09955-04011)

Claw No.1

PP–35

PP (09957-04010)

Attachment

(09958-04011)

Holder

09950-60010

Replacer Set

(09951-00370)

Replacer 37

(09951-00500)

Replacer 50

(09951-00630)

Replacer 63

09950-60020

Replacer Set No.2

(09951-00710)

Replacer 71

09950-70010

Handle Set

(09951-07100)

Handle 100


PP–36

PREPARATION – AXLE

RECOMMENDED TOOLS 09905-00013

PP

Snap Ring Pliers


PREPARATION – AXLE

PP–37

EQUIPMENT Dial indicator with magnetic base Torque wrench

PP


PREPARATION – SUSPENSION

PP–37

SUSPENSION PREPARATION

SST 09023-00100

Union Nut Wrench 10 mm

09023-00101

Union Nut Wrench 10 mm

09223-15020

Oil Seal & Bearing Replacer

09612-30012

Steering Worm Bearing Puller

09628-00011

Ball Joint Puller

09727-30021

Coil Spring Compressor

(09727-00010)

Bolt Set

(09727-00021)

Arm Set

(09727-00031)

Compressor

09950-40011

Puller B Set

(09951-04020)

Hanger 200

PP


PP–38

PREPARATION – SUSPENSION (09952-04010)

Slide Arm

(09953-04030)

Center Bolt 200

(09954-04020)

Arm 100

(09954-04030)

Arm 150

(09955-04011)

Claw No.1

(09955-04051)

Claw No.5

(09957-04010)

Attachment

(09958-04011)

Holder

09950-60010

Replacer Set

(09951-00590)

Replacer 59

PP

09950-60020

Replacer Set No.2

(09387-02010)

Oil Seal Replacer


PREPARATION – SUSPENSION (09951-00810)

PP–39

Replacer 81

PP


PP–40

PREPARATION – SUSPENSION

RECOMMENDED TOOLS 09040-00011

(09043-20060)

PP

Hexagon Wrench Set

Socket Hexagon Wrench 6


PREPARATION – SUSPENSION

PP–41

EQUIPMENT Alignment tester Angle gauge Camber-caster-kingpin gauge Tire pressure gauge Toe-in gauge Wheel balancer Dial indicator with magnetic base Torque wrench Drill

PP


PP–40

TIRE AND WHEEL PREPARATION

EQUIPMENT Dial indicator with magnetic base Tire pressure gauge Wheel balancer

PP

PREPARATION – TIRE AND WHEEL


PREPARATION – BRAKE CONTROL

PP–41

BRAKE CONTROL PREPARATION

SST 09023-00100

Union Nut Wrench 10 mm

09214-76011

Crankshaft Pulley Replacer

09520-00031

Rear Axle Shaft Puller

(09520-00040)

Shocker

09521-00020

Drive Shaft Boot Clamping Tool

09950-00020

Bearing Remover

PP


PP–42

PREPARATION – BRAKE CONTROL

RECOMMENDED TOOLS

PP

09082-00040

TOYOTA Electrical Tester

(09083-00150)

Test Lead Set


PREPARATION – BRAKE CONTROL

PP–43

EQUIPMENT Torque wrench

PP


PP–42

PREPARATION – BRAKE

BRAKE PREPARATION

SST

PP

09023-00100

Union Nut Wrench 10 mm

09703-30010

Brake Shoe Return Spring Tool

09709-29018

LSPV Gauge Set

09718-00010

Shoe Hold Down Spring Driver

09737-00013

Brake Booster Push Rod Gauge

09737-00020

Brake Booster Push Rod Wrench


PREPARATION – BRAKE

PP–43

RECOMMENDED TOOLS 09031-00030

Pin Punch

PP


PP–44

EQUIPMENT Torque wrench Ruler Micrometer Dial indicator with magnetic base Brake drum gauge

PP

Slide caliper

PREPARATION – BRAKE


PP–45

PREPARATION – BRAKE

LUBRICANT Item

Capacity

Classification

Brake fluid

-

SAE J1703 or FMVSS No. 116 DOT3

PP


PREPARATION – PARKING BRAKE

PP–43

PARKING BRAKE PREPARATION

EQUIPMENT Torque wrench Ohmmeter

PP


PP–44

PREPARATION – STEERING COLUMN

STEERING COLUMN PREPARATION

SST

PP

09950-50013

Puller C Set

(09951-05010)

Hanger 150

(09952-05010)

Slide Arm

(09953-05020)

Center Bolt 150

(09954-05021)

Claw No.2


PREPARATION – STEERING COLUMN

PP–45

RECOMMENDED TOOLS 09042-00010

Torx Socket T30

PP


PP–46

EQUIPMENT Torque wench Drill

PP

PREPARATION – STEERING COLUMN


PREPARATION – POWER STEERING

PP–45

POWER STEERING PREPARATION

SST 09670-00010

Front Crossmember Guide Tool

09670-00011

Front Crossmember Guide Tool

PP


PP–46

PREPARATION – POWER STEERING

RECOMMENDED TOOLS 09082-00040

(09083-00150)

PP

TOYOTA Electrical Tester

Test Lead Set


PREPARATION – POWER STEERING

PP–47

EQUIPMENT Torque wrench

PP


PP–46

PREPARATION – AIR CONDITIONING

AIR CONDITIONING PREPARATION

SST 07110-58060

PP

Air Conditioner Service Tool Set

-

(07117-58080)

Quick Disconnect Adapter

-

(07117-58090)

Quick Disconnect Adapter

-

(07117-78050)

Refrigerant Charging Gauge

-

(07117-88060)

Refrigerant Charging Hose

-

(07117-88070)

Refrigerant Charging Hose

-

(07117-88080)

Refrigerant Charging Hose

-


PP–47

PREPARATION – AIR CONDITIONING

RECOMMENDED TOOLS 09082-00040

(09083-00150)

TOYOTA Electrical Tester

-

Test Lead Set

-

PP


PP–48

EQUIPMENT Hexagon wrench 4mm Hexagon wrench 14mm Ohmmeter Vinyl tape Torque wrench

PP

Service wire harness

PREPARATION – AIR CONDITIONING


PREPARATION – AIR CONDITIONING

PP–49

LUBRICANT Item

Capacity

Classification

Compressor oil

-

ND-OIL8 or the equivalent

When replacing cooler evaporator subassembly

40 cc (1.35 fl. oz.)

ND-OIL8 or the equivalent

When replacing condenser

40 cc (1.35 fl. oz.)

ND-OIL8 or the equivalent

PP


PP–48

PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM

SUPPLEMENTAL RESTRAINT SYSTEM PREPARATION

SST

PP

09082-00030

TOYOTA Electrical Tester.

09082-00700

SRS Airbag Deployment Tool

09082-00760

Airbag Deployment Wire Sub-harness No.4

09082-00780

Airbag Deployment Wire Sub-harness No.6

09082-00802

Airbag Deployment Wire Sub-Harness No. 8

(09082-10801)

Wire A

(09082-20801)

Wire B

(09082-30801)

Wire C

09082-00810

Airbag Deployment Wire Sub-Harness No. 9

09843-18060

SRS Check Wire


PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM

PP–49

RECOMMENDED TOOLS 09042-00010

Torx Socket T30

09082-00040

TOYOTA Electrical Tester

PP (09083-00150)

Test Lead Set


PP–50

EQUIPMENT Battery Bolt Knife Ohmmeter Plastic bag

PP

Service-purpose wire harness Shop rag or pice of cloth Tire Tire with disk wheel Torque wrench Service wire harness

PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM


PP–50

PREPARATION – SEAT BELT

SEAT BELT PREPARATION

SST

PP

09082-00700

SRS Airbag Deployment Tool

09082-00770

Airbag Deployment Wire Sub-harness No.5


PREPARATION – SEAT BELT

PP–51

RECOMMENDED TOOLS 09082-00040

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set

PP


PP–52

EQUIPMENT Battery Knife Ohmmeter Plastic bag Protective tape

PP

Service-purpose wire harness Service wire harness Tire with wheel Torque wrench

PREPARATION – SEAT BELT


PREPARATION – THEFT DETERRENT SYSTEM

PP–51

THEFT DETERRENT SYSTEM PREPARATION

RECOMMENDED TOOLS 09082-00040

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set

PP


PP–52

EQUIPMENT Ohmmeter Torque wrench

PP

PREPARATION – THEFT DETERRENT SYSTEM


PP–52

PREPARATION – ENGINE IMMOBILISER

ENGINE IMMOBILISER PREPARATION

RECOMMENDED TOOLS 09082-00040

PP

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set


PREPARATION – CRUISE CONTROL

PP–53

CRUISE CONTROL PREPARATION

RECOMMENDED TOOLS 09082-00040

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set

PP


PP–54

EQUIPMENT Torque wrench

PP

PREPARATION – CRUISE CONTROL


PP–54

PREPARATION – LIGHTING

LIGHTING PREPARATION

RECOMMENDED TOOLS 09042-00010

Torx Socket T30

09082-00040

TOYOTA Electrical Tester

PP

(09083-00150)

Test Lead Set


PREPARATION – LIGHTING

PP–55

EQUIPMENT Battery Ohmmeter Voltmeter Protective tape Service wire harness Torque wrench

PP


PREPARATION – WIPER AND WASHER

PP–55

WIPER AND WASHER PREPARATION

RECOMMENDED TOOLS 09082-00040

TOYOTA Electrical Tester

PP (09083-00150)

Test Lead Set


PP–56

EQUIPMENT Battery Ohmmeter Protective tape Brush Service wire harness

PP

Torque wrench

PREPARATION – WIPER AND WASHER


PP–56

PREPARATION – DOOR LOCK

DOOR LOCK PREPARATION

RECOMMENDED TOOLS

PP

09042-00010

Torx Socket T30

09082-00040

TOYOTA Electrical Tester

(09083-00150)

Test Lead Set


PREPARATION – DOOR LOCK

PP–57

EQUIPMENT Ohmmeter Protective tape Service wire harness MP grease Torque wrench

PP


PP–58

PREPARATION – DOOR LOCK

SSM 08833-00070

PP

Adhesive 1324, THREE BOND 1324 or equivalent


PP–57

PREPARATION – METER

METER PREPARATION

RECOMMENDED TOOLS 09082-00040

(09083-00150)

TOYOTA Electrical Tester

-

Test Lead Set

-

PP


PP–58

PREPARATION – METER

EQUIPMENT Ohmmeter Torque wrench Tape

PP

To avoid surface damage


PP–58

PREPARATION – AUDIO / VISUAL

AUDIO / VISUAL PREPARATION

RECOMMENDED TOOLS 09050-00032

PP

Air Drill

(09050-00210)

Chuck Set

(09050-00220)

Handle

(09050-02010)

Dust Cap

(09050-02020)

Nose Piece No.1

09050-20010

Air Riveter

09060-60350

Rivet Cutter

09082-00040

TOYOTA Electrical Tester

(09083-00150)

Test Lead Set


PREPARATION – AUDIO / VISUAL

PP–59

EQUIPMENT Masking tape Fine tip brush Grease Ohmmeter Protective tape Torque wrench Wax or silicone remover

PP


PREPARATION – HORN

PP–59

HORN PREPARATION

RECOMMENDED TOOLS 09082-00040

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set

PP


PP–60

EQUIPMENT Battery Ohmmeter Protective tape Service wire harness Torque wrench

PP

PREPARATION – HORN


PP–60

OTHER SYSTEM PREPARATION

EQUIPMENT Torque wrench

PP

PREPARATION – OTHER SYSTEM


PREPARATION – WINDSHIELD / WINDOWGLASS

PP–61

WINDSHIELD / WINDOWGLASS PREPARATION

RECOMMENDED TOOLS 09041-00020

Torx Driver T25

09082-00040

TOYOTA Electrical Tester

(09083-00150)

Test Lead Set

PP


PP–62

EQUIPMENT Protective tape Ammeter Ohmmeter Knife Piano wire

PP

Sealer gun Suction cup Wooden block Brush Sponge Voltmeter MP grease Torque wrench

PREPARATION – WINDSHIELD / WINDOWGLASS


PREPARATION – WINDSHIELD / WINDOWGLASS

PP–63

SSM 08850-00801

Windshield Glass Adhesive Set or equivalent

PP


PP–62

PREPARATION – MIRROR

MIRROR PREPARATION

RECOMMENDED TOOLS 09070-20010

PP

Moulding Remover


PREPARATION – MIRROR

PP–63

EQUIPMENT Ohmmeter Protective tape Torque wrench

PP


PREPARATION – INSTRUMENT PANEL

PP–63

INSTRUMENT PANEL PREPARATION

EQUIPMENT Torque wrench Tape

To avoid surface damage

PP


PP–64

PREPARATION – SEAT

SEAT PREPARATION

RECOMMENDED TOOLS

PP

09042-00050

Torx Socket T45

09044-00020

Torx Socket E10


PREPARATION – SEAT

PP–65

EQUIPMENT Clip remover Hog ring pliers Protective tape Torque wrench

PP


PREPARATION – ENGINE HOOD / DOOR

PP–65

ENGINE HOOD / DOOR PREPARATION

SST 09812-00010

Door Hinge Set Bolt Wrench

PP


PP–66

PREPARATION – ENGINE HOOD / DOOR

RECOMMENDED TOOLS 09041-00020

Torx Driver T25

09042-00010

Torx Socket T30

09042-00020

Torx Socket T40

PP


PREPARATION – ENGINE HOOD / DOOR

PP–67

EQUIPMENT Protective tape MP grease Torque wrench

PP


PP–68

PREPARATION – ENGINE HOOD / DOOR

SSM

PP

08833-00070

Adhesive 1324, THREE BOND 1324 or equivalent

08850-00065

Butyl Tape Set


PP–66

PREPARATION – EXTERIOR

EXTERIOR PREPARATION

RECOMMENDED TOOLS 09070-20010

PP

Moulding Remover


PREPARATION – EXTERIOR

PP–67

EQUIPMENT Clip remover Double-sided adhesive tape Infrared light Protective tape Shop rag or piece of cloth Squeegee Torque wrench

PP


PREPARATION – INTERIOR

PP–67

INTERIOR PREPARATION

RECOMMENDED TOOLS 09070-20010

Moulding Remover

PP


PP–68

EQUIPMENT Clip remover Protective cover Protective tape Tape Torque wrench

PP

PREPARATION – INTERIOR


PP–68

PREPARATION – CAN COMMUNICATION

CAN COMMUNICATION PREPARATION

RECOMMENDED TOOLS 09082-00040

PP

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set


SB–1

SEAT BELT – FRONT PASSENGER SEAT BELT WARNING LIGHT (for Sedan)

FRONT PASSENGER SEAT BELT WARNING LIGHT (for Sedan) SEAT BELT RESTRAINTS

COMPONENTS HAZARD WARNING SIGNAL SWITCH CONNECTOR

INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY

for Integrated with Panel:

x4 RADIO RECEIVER ASSEMBLY

INSTRUMENT CLUSTER FINISH PANEL

INSTRUMENT PANEL FINISH PANEL END RH

INSTRUMENT PANEL FINISH PANEL END LH INSTRUMENT PANEL LOWER CENTER FINISH PANEL B138696E01

SB


SB–2

SEAT BELT – FRONT PASSENGER SEAT BELT WARNING LIGHT (for Sedan)

INSTRUMENT PANEL CENTER REGISTER ASSEMBLY

SB

HAZARD WARNING SIGNAL SWITCH ASSEMBLY (Built in Front Passenger Seat Belt Warning Light)

w/ Radio Receiver:

INSTRUMENT PANEL CENTER REGISTER ASSEMBLY

HAZARD WARNING SIGNAL SWITCH ASSEMBLY (Built in Front Passenger Seat Belt Warning Light)

B138572E01


SEAT BELT – FRONT PASSENGER SEAT BELT WARNING LIGHT (for Sedan)

SB–3

REMOVAL 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2.

REMOVE INSTRUMENT PANEL LOWER CENTER FINISH PANEL (See page ME-138)

3.

REMOVE INSTRUMENT PANEL FINISH PANEL END RH (See page ME-138)

4.

REMOVE INSTRUMENT PANEL FINISH PANEL END LH (See page ME-138)

5.

REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page ME-139)

6.

REMOVE RADIO RECEIVER ASSEMBLY (for Integrated with Panel) (See page AV-38)

7.

REMOVE INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY (except Integrated with Panel) (See page IP-43)

8.

REMOVE INSTRUMENT PANEL CENTER REGISTER ASSEMBLY (See page LI-166)

9.

REMOVE HAZARD WARNING SIGNAL SWITCH ASSEMBLY (Built in Front Passenger Seat Belt Warning Light) (a) Disengage the 3 claws and remove the hazard warning signal switch.

B138529

INSPECTION 1.

Battery B134920E01

INSPECT HAZARD WARNING SIGNAL SWITCH ASSEMBLY (Built in Front Passenger Seat Belt Warning Light) (a) Check the operation. (1) Apply battery voltage to the terminals and check that the indicator illuminates. Standard Condition

Standard

Positive battery - Terminal 6 (lG+) Negative battery - Terminal 8 (PBEW)

Illuminates

If the result is not as specified, replace the hazard warning signal switch.

SB


SB–4

SEAT BELT – FRONT PASSENGER SEAT BELT WARNING LIGHT (for Sedan)

INSTALLATION

SB

1.

INSTALL HAZARD WARNING SIGNAL SWITCH ASSEMBLY (Built in Front Passenger Seat Belt Warning Light) (a) Engage the 3 claws and install the hazard warning signal switch.

2.

INSTALL INSTRUMENT PANEL CENTER REGISTER ASSEMBLY (See page LI-168)

3.

INSTALL RADIO RECEIVER ASSEMBLY (for Integrated with Panel) (See page AV-40)

4.

INSTALL INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY (except Integrated with Panel) (See page IP-56)

5.

INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page ME-140)

6.

INSTALL INSTRUMENT PANEL FINISH PANEL END RH (See page ME-141)

7.

INSTALL INSTRUMENT PANEL FINISH PANEL END LH (See page ME-141)

8.

INSTALL INSTRUMENT PANEL LOWER CENTER FINISH PANEL (See page ME-142)

9.

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

B138529


SEAT BELT – FRONT PASSENGER SEAT BELT WARNING LIGHT (for Hatchback)

SB–5

FRONT PASSENGER SEAT BELT WARNING LIGHT (for Hatchback) SEAT BELT RESTRAINTS

COMPONENTS

SB

FRONT PASSENGER SEAT BELT WARNING LIGHT CONNECTOR

FRONT PASSENGER SEAT BELT WARNING LIGHT

INSTRUMENT PANEL FINISH PANEL END

B117689E01


SB–6

SEAT BELT – FRONT PASSENGER SEAT BELT WARNING LIGHT (for Hatchback)

REMOVAL 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2.

REMOVE INSTRUMENT PANEL FINISH PANEL END (See page ME-145)

3.

REMOVE FRONT PASSENGER SEAT BELT WARNING LIGHT (a) Disengage the 2 claws and remove the front passenger seat belt warning light.

SB

B114416

INSPECTION 1.

Battery B126913E01

INSPECT FRONT PASSENGER SEAT BELT WARNING LIGHT (a) Check the operation. (1) Apply battery voltage to the terminals and check that the indicator illuminates. Standard Condition

Standard

Positive battery - Terminal 6 (IG+) Negative battery - Terminal 3 (PBELT)

Illuminates

If the result is not as specified, replace the front passenger seat belt warning light.

INSTALLATION

B114416

1.

INSTALL FRONT PASSENGER SEAT BELT WARNING LIGHT (a) Engage the 2 claws and install the front passenger seat belt warning light.

2.

INSTALL INSTRUMENT PANEL FINISH PANEL END (See page ME-149)

3.

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)


SEAT BELT – SEAT BELT WARNING SYSTEM

SB–7

SEAT BELT WARNING SYSTEM SEAT BELT RESTRAINTS

PARTS LOCATION HATCHBACK: COMBINATION METER ASSEMBLY

SB

W/O TACHOMETER:

FRONT DRIVER SEAT BELT WARNING LIGHT

W/ TACHOMETER:

FRONT PASSENGER SEAT BELT WARNING LIGHT

CENTER AIRBAG SENSOR ASSEMBLY

MAIN BODY ECU (INSTRUMENT PANEL J/B) - GAUGE FUSE B143853E02


SB–8

SEAT BELT – SEAT BELT WARNING SYSTEM

SEDAN:

COMBINATION METER ASSEMBLY W/O TACHOMETER:

SB

FRONT DRIVER SEAT BELT WARNING LIGHT W/ TACHOMETER:

FRONT PASSENGER SEAT BELT WARNING LIGHT

FRONT DRIVER SEAT BELT WARNING LIGHT

CENTER AIRBAG SENSOR ASSEMBLY

MAIN BODY ECU (INSTRUMENT PANEL J/B) - GAUGE FUSE

B143851E01


SEAT BELT – SEAT BELT WARNING SYSTEM

SB–9

REAR OCCUPANT CLASSIFICATION SENSOR RH FRONT OCCUPANT CLASSIFICATION SENSOR RH OCCUPANT CLASSIFICATION ECU

SB FRONT OCCUPANT CLASSIFICATION SENSOR LH

FRONT SEAT INNER BELT ASSEMBLY LH

FRONT SEAT INNER BELT ASSEMBLY RH

REAR OCCUPANT CLASSIFICATION SENSOR LH

B118460E01


SB–10

SEAT BELT – SEAT BELT WARNING SYSTEM

SYSTEM DIAGRAM

SB

Front Driver Seat Belt Warning Light

Combination Meter Assembly

Instrument Panel Finish Panel End RH*1

Seat Belt Warning Buzzer for Driver Side and Passenger Side

Front Passenger Seat Belt Warning Light

Hazard Warning Signal Switch Assembly*2

Main Body ECU

CAN Communication Line

Center Airbag Sensor Assembly

Front Seat Inner Belt Assembly LH

Front Passenger Seat Belt Warning Light

Occupant Classification ECU

Occupant Classification Sensors (Front Passenger Side)

Front Seat Inner Belt Assembly RH

*1: Hatchback *2: Sedan

B143852E01

Communication table: Sender

Receiver

Signal

Line

Center airbag sensor assembly

Main body ECU

Front seat inner belt switch signal (driver side)

CAN communication line


SBâ&#x20AC;&#x201C;11

SEAT BELT â&#x20AC;&#x201C; SEAT BELT WARNING SYSTEM Sender

Receiver

Signal

Line

Center airbag sensor assembly

Main body ECU

Front seat inner belt switch signal (passenger side)

CAN communication line

Main body ECU

Combination meter assembly

Front seat inner belt switch signal (driver side)

CAN communication line

Main body ECU

Combination meter assembly

Front seat inner belt switch signal (passenger side)

CAN communication line

SB


SB–12

SEAT BELT – SEAT BELT WARNING SYSTEM

SYSTEM DESCRIPTION 1.

2.

SB

SEAT BELT WARNING SYSTEM DESCRIPTION If a seat belt is not fastened, this system flashes the seat belt warning light and sounds the seat belt warning buzzer as a reminder. FUNCTIONS OF MAIN COMPONENTS

Components

Function

Front Seat Inner Belt Assembly LH

Informs center airbag sensor assembly of front driver seat belt condition (fastened or unfastened)

Front Seat Inner Belt Assembly RH

Informs occupant classification ECU of front passenger seat belt condition (fastened or unfastened)

Occupant Classification ECU

Informs center airbag sensor assembly of front passenger seat condition (occupied or unoccupied) Informs center airbag sensor assembly of front passenger seat belt condition (fastened or unfastened)

Occupant Classification Sensor

Informs occupant classification ECU of front passenger seat condition (occupied or unoccupied)

Main Body ECU

Informs combination meter assembly of front driver and front passenger seat belt condition (fastened or unfastened) Informs combination meter assembly of front passenger seat condition (occupied or unoccupied)

Front Driver Seat Belt Warning Light

If front driver seat belt is unfastened and ignition switch is ON, combination meter assembly flashes seat belt warning light of combination meter assembly as reminder

Front Passenger Seat Belt Warning Light

Hatchback: When front passenger seat is occupied and ignition switch is ON, if passenger seat belt is unfastened, combination meter assembly flashes front passenger seat belt warning light of instrument panel finish panel end RH as reminder Sedan: When front passenger seat is occupied and ignition switch is ON, if passenger seat belt is unfastened, combination meter assembly flashes front passenger seat belt warning light of hazard warning signal switch assembly as reminder

Seat Belt Warning Buzzer for Front Driver Side and Front Passenger Side

If front driver or front passenger seat belt is unfastened and ignition switch is ON, combination meter assembly sounds buzzer as reminder

3.

SYSTEM OPERATION • When the ignition switch is ON, this system detects the condition of the seat belts based on signals from the front seat inner belt switches (for driver and front passenger seats) and the occupant classification sensor (front passenger side only).


SB–13

SEAT BELT – SEAT BELT WARNING SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the seat belt warning system. • *: Use the intelligent tester.

1

SB VEHICLE BROUGHT TO WORKSHOP

NEXT

2

INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding.

NEXT

3

CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM* (a) Use the intelligent tester to check if the CAN communication system is functioning normally. Result:

B

Result

Proceed to

DTC is not output

A

DTC is output

B

GO TO CAN COMMUNICATION SYSTEM

A

4

PROBLEM SYMPTOMS TABLE Result: Result

Proceed to

Fault is not listed in problem symptoms table

A

Fault is listed in problem symptoms table

B

B

Go to step 6

A

5

OVERALL ANALYSIS AND TROUBLESHOOTING* (a) DATA LIST / ACTIVE TEST (see page SB-20)


SB–14

SEAT BELT – SEAT BELT WARNING SYSTEM

(b) TERMINALS OF ECU (see page SB-14) NEXT

6

SB

REPAIR OR REPLACE

NEXT

7 NEXT END

CONFIRMATION TEST


SB–15

SEAT BELT – SEAT BELT WARNING SYSTEM

CUSTOMIZE PARAMETERS HINT: The following item can be customized. Combination Meter Assembly Display (Item)

Default

Function

Setting

SEAT BELT WARN

D/P ON

Changes seat belt warning buzzer setting

D/P ON / D ON / P ON / D/P OFF

NOTICE: • When the customer requests the modification of a function, first make sure that the function(s) can be customized. • Record the current settings before customizing. • When troubleshooting a function, first make sure that the function is not set to OFF.

SB


SBâ&#x20AC;&#x201C;16

SEAT BELT â&#x20AC;&#x201C; SEAT BELT WARNING SYSTEM

PROBLEM SYMPTOMS TABLE

SB

HINT: Use the table below to help determine the causes of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Seat belt warning system Symptom

Front driver seat belt warning light does not operate

Suspected area Front seat inner belt assembly LH (for Hatchback)

SB-40

Front seat inner belt assembly LH (for Sedan)

SB-34

Wire harness

SB-22

Center airbag sensor assembly

SB-22

Main body ECU

SB-22

Combination meter assembly

SB-22

Fuse

SB-24

Front passenger seat belt warning light (for Hatchback)

SB-6

Front passenger seat belt warning light (for Sedan)

SB-3

Front seat inner belt assembly RH (for Hatchback)

SB-40

Front seat inner belt assembly RH (for Sedan) Front passenger seat belt warning light does not operate

Seat belt warning buzzer does not sound (Front driver and front passenger seat belt warning lights operate normally)

See page

Occupant classification sensor

SB-34 RS-226

Wire harness

SB-24

Occupant classification ECU

SB-24

Center airbag sensor assembly

SB-24

Main body ECU

SB-24

Combination meter assembly

SB-24

Combination meter assembly (for Hatchback)

ME-73

Combination meter assembly (for Sedan)

ME-10


SBâ&#x20AC;&#x201C;17

SEAT BELT â&#x20AC;&#x201C; SEAT BELT WARNING SYSTEM

TERMINALS OF ECU 1.

COMBINATION METER ASSEMBLY

Hatchback: D2

D1

SB                        

               

B127205E04

Sedan: D76

D1

                       

                                       

E126885E06

(a) Disconnect the D1 combination meter assembly connector. (b) Measure the voltage and resistance of the wire harness side connector. Standard Symbols (Terminal No.)

Wiring Color

Terminal Description

Condition

Specified Condition

D1-1 - Body ground

B - Body ground

Ignition switch signal

Ignition switch OFF â&#x2020;&#x2019; ON

Below 1 V â&#x2020;&#x2019; 11 to 14 V

D1-2 - Body ground

L - Body ground

Battery

Always

11 to 14 V

D1-24 - Body ground

BR - Body ground

Ground

Always

Below 1 â&#x201E;Ś

If the result is not as specified, there may be a malfunction in the wire harness. (c) Reconnect the combination meter assembly connector. (d) Measure the voltage of the wire harness side connector. Standard voltage Symbols (Terminal No.)

Wiring Color

Terminal Description

Condition

Specified Condition

D1-20 - Body ground

G - Body ground

CAN communication line

Ignition switch ON

Pulse generation (See waveform 1)

D1-21 - Body ground

W - Body ground

CAN communication line

Ignition switch ON

Pulse generation (See waveform 2)

O - Body ground

Seat belt warning light signal (Front passenger side)

Ignition switch ON Front passenger seat is occupied and its seat belt is unfastened

Alternating between 11 to 14 V and below 1 V

O - Body ground

Seat belt warning light signal (Front passenger side)

Ignition switch ON Front passenger seat is occupied and its seat belt is fastened

Below 1 V

D2-9*1 - Body ground

D2-9*1 - Body ground


SB–18

SEAT BELT – SEAT BELT WARNING SYSTEM

Symbols (Terminal No.)

D76-9*2 - Body ground

D76-9*2 - Body ground

Wiring Color

Terminal Description

Condition

Specified Condition

O - Body ground

Seat belt warning light signal (Front passenger side)

Ignition switch ON Front passenger seat is occupied and its seat belt is unfastened

Alternating between 11 to 14 V and below 1 V

O - Body ground

Seat belt warning light signal (Front passenger side)

Ignition switch ON Front passenger seat is occupied and its seat belt is fastened

Below 1 V

SB

*1: Hatchback *2: Sedan If the result is not as specified, the combination meter may have a malfunction. (e) Waveform 1 (Reference): Using an oscilloscope CAN communication signal

1 V/DIV.

Terminal Name

D1-21 (CANL) - D1-24 (ET)

Tester Range

1V/DIV, 10µs/DIV

Condition

Ignition switch ON

GND 10 Ǵsec./DIV.

A086154E11

(f) 1 V/DIV.

Waveform 2 (Reference): Using an oscilloscope CAN communication signal Terminal Name

2.

D1-21 (CANL) - D1-24 (ET)

Tester Range

1V/DIV, 10µs/DIV

Condition

Ignition switch ON

CENTER AIRBAG SENSOR ASSEMBLY

GND 10 Ǵsec./DIV. A086155E12

Center Airbag Sensor Assembly:

D16

J8

J9

B148514E01

Terminal No.

Terminal Symbol

D16-13

CANH

Destination CAN communication line

D16-21

IG2

D16-22

CANL

IGN fuse

D16-25

E1

Ground

D16-26

E2

Ground

CAN communication line

J8-11

DBE+

Front seat inner belt assembly LH

J8-12

DBE-

Front seat inner belt assembly LH

J9-12

FSP+

Occupant Classification ECU


SB–19

SEAT BELT – SEAT BELT WARNING SYSTEM Terminal No.

Terminal Symbol

J9-13

FSP-

3. Occupant Classification ECU:

Destination Occupant Classification ECU

OCCUPANT CLASSIFICATION ECU

U1

J24

SB

H100909E04

(a) Disconnect the J24 occupant classification ECU connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.)

Wiring Color

Terminal Description

Condition

Specified Condition

J24-7 (IG) - J24-3 (GND)

O - W-B

Power source (IG2 Fuse)

Ignition switch OFF

Below 1 V

J24-7 (IG) - J24-3 (GND)

O - W-B

Power source (IG2 Fuse)

Ignition switch ON

11 to 14 V

J24-1 (+B) - Body ground

V - Body ground

Power source (ECU-B Fuse)

Always

11 to 14 V

J24-3 (GND) - Body ground

W-B - Body ground

Ground

Always

Below 1 Ω

If the result is not as specified, there may be a malfunction in the wire harness. (c) Reconnect the occupant classification ECU connector. (d) Measure the voltage of the connector. Symbols (Terminal No.)

Wiring Color

Terminal Description

Condition

Specified Condition

BSW (J24-9) - BGND (J24-5)

O-P

Passenger side buckle switch line

Buckle switch ON Buckle switch OFF

Pulse generation

FSR+ (J24-8) - FSR- (J244)

GR - Y

Center airbag sensor assembly communication line

Ignition switch ON

Pulse generation

If the result is not as specified, the combination meter may have a malfunction.

DIAGNOSIS SYSTEM CG SG CANH SIL

CANL

1.

CHECK DLC3 (a) The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format.

BAT H100769E16

Symbols (Terminal No.)

Terminal Description

Condition

Specified Condition

SIL (7) - SG (5)

Bus " +" line

During transmission

Pulse generation

CG (4) - Body ground

Chassis ground

Always

Below 1 Ω


SB–20

SB

SEAT BELT – SEAT BELT WARNING SYSTEM

Symbols (Terminal No.)

Terminal Description

Condition

Specified Condition

SG (5) - Body ground

Signal ground

Always

Below 1 Ω

BAT (16) - Body ground

Battery positive

Always

11 to 14 V

CANH (6) - CANL (14)

CAN bus line

Ignition switch OFF*

54 to 69 Ω

CANH (6) - CG (4)

HIGH-level CAN bus line

Ignition switch OFF*

200 Ω or higher

CANL (14) - CG (4)

LOW-level CAN bus line

Ignition switch OFF*

200 Ω or higher

CANH (6) - BAT (16)

HIGH-level CAN bus line

Ignition switch OFF*

6 kΩ or higher

CANL (14) - BAT (16)

LOW-level CAN bus line

Ignition switch OFF*

6 kΩ or higher

Hatchback: Intelligent Tester

DLC3 CAN VIM

Sedan:

Intelligent Tester

2. DLC3 CAN VIM B133416E01

3.

4.

NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the CAN VIM, connect the CAN VIM to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. INSPECT FRONT DRIVER SEAT BELT WARNING LIGHT (a) Turn the ignition switch ON. (b) When the driver seat belt is not fastened, check that the combination meter assembly driver seat belt warning light blinks. (c) When the seat belt is fastened, check that the combination meter assembly driver side seat belt warning light turns off. INSPECT FRONT PASSENGER SEAT BELT WARNING LIGHT (a) Turn the ignition switch ON.


SEAT BELT â&#x20AC;&#x201C; SEAT BELT WARNING SYSTEM

5.

6.

SBâ&#x20AC;&#x201C;21

(b) When the front passenger seat is occupied, but the seat belt is not fastened, check that the front passenger seat belt warning light on the instrument panel finish panel end RH*1 or hazard warning signal switch assembly*2 blinks. *1: Hatchback *2: Sedan (c) When the front passenger seat belt is fastened, check that the front passenger seat belt warning light turns off. INSPECT SEAT BELT WARNING BUZZER USING DRIVER SEAT BELT (a) Turn the ignition switch ON. (b) When the driver seat belt is not fastened within 1.8 seconds of the ignition switch being turned ON, check that the seat belt warning buzzer sounds at 1.2 second intervals for 6 seconds. (c) When the driver seat belt is not fastened within 13.8 seconds of the ignition switch being turned ON and the vehicle speed reaches 12.4 mph (20 km/h) or more, check that the buzzer sounds at 1.2 second intervals for 9.6 seconds. (d) After the buzzer has sounded for 9.6 seconds, check that the buzzer sounds at 0.4 second intervals for a further 20 seconds. (e) When 29.6 seconds have elapsed since the buzzer started sounding in step (c) above, check that the buzzer stops sounding. (f) After the buzzer has stopped sounding, turn the ignition switch OFF and then start the engine again. With the driver seat belt unfastened, drive the vehicle at 12.4 mph (20 km/h) or more. Check that the buzzer sounds. (g) After the buzzer has stopped sounding, fasten the driver seat belt, drive the vehicle at 12.4 mph (20 km/h) or more, and then unfasten the seat belt. Check that the buzzer sounds. (h) After the buzzer has stopped sounding, move the shift lever to R. Then move the shift lever to D (for A/ T only). With the driver seat belt unfastened, drive the vehicle at 12.4 mph (20km/h) or more. Check that the buzzer sounds. INSPECT SEAT BELT WARNING BUZZER USING FRONT PASSENGER SEAT BELT HINT: If the following inspection is conducted by one person, since the front passenger seat belt warning buzzer function uses signals from the occupant classification sensors, place an object with a weight of 36 kg (79.37 lb) or more on the front passenger seat. (a) Turn the ignition switch ON.

SB


SBâ&#x20AC;&#x201C;22

SB

SEAT BELT â&#x20AC;&#x201C; SEAT BELT WARNING SYSTEM

(b) When the front passenger seat belt is not fastened within 1.8 seconds of the ignition switch being turned ON, check that the seat belt warning buzzer sounds at 1.2 second intervals for 6 seconds. (c) When the front passenger seat belt is not fastened within 13.8 seconds of the ignition switch being turned ON and the vehicle speed reaches 12.4 mph (20 km/h) or more, check that the buzzer sounds at 1.2 second intervals for 9.6 seconds. (d) After the buzzer has sounded for 9.6 seconds, check that the buzzer sounds at 0.4 second intervals for a further 20 seconds. (e) When 29.6 seconds have elapsed since the buzzer started sounding in step (c) above, check that the buzzer stops sounding. (f) After the buzzer has stopped sounding, turn the ignition switch OFF and then start the engine again. With the front passenger seat belt unfastened, drive the vehicle at 12.4 mph (20 km/h) or more. Check that the buzzer sounds. (g) After the buzzer has stopped sounding, fasten the front passenger seat belt, drive the vehicle at 12.4 mph (20 km/h) or more, and then unfasten the front passenger seat belt. Check that the buzzer sounds. (h) After the buzzer has stopped sounding, move the shift lever to R. Then move the shift lever to D. With the front passenger seat belt unfastened, drive the vehicle at 12.4 mph (20km/h) or more. Check that the buzzer sounds.


SB–23

SEAT BELT – SEAT BELT WARNING SYSTEM

DATA LIST / ACTIVE TEST 1.

READ DATA LIST HINT: By accessing the DATA LIST using the intelligent tester, values of the switches and sensors can be read without removing any parts. Reading the DATA LIST is the first step of troubleshooting and is one method of shortening labor time. (a) Connect the intelligent tester with the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the DATA LIST by following the prompts displayed on the tester screen.

Center Airbag Sensor Assembly Measurement Item/ Range (Display)

Normal Condition

Diagnostic Note

D BUCKLE SW

Buckle switch (Driver side)/ UNSET: Seat belt not fastened SET: Seat belt fastened NG: Data not determined

UNSET/SET

-

P BUCKLE SW

Buckle switch (Passenger side)/ UNSET: Seat belt not fastened SET: Seat belt fastened NG: Data not determined

UNSET/SET

-

Normal Condition

Diagnostic Note

UNSET/SET

-

AF05/AM50/CHILD/CRS/OFF

-

Item

Occupant Classification ECU Item

P BUCKLE SW

PASSENGER CLASS

Measurement Item/ Range (Display) Buckle switch (Front passenger side)/ UNSET: Front passenger side seat belt is unfastened SET: Front passenger side seat belt is fastened NG: Front passenger side seat belt is malfunctioning Front passenger classification/ AF05: Adult (36 to 54 kg (79.37 to 119.05 lb)) is seated AM50: Adult more than 54 kg (119.05 lb) is seated CHILD: Child (less than 36 kg (79.37 lb)) is seated CRS: Child restraint system (less than 7 kg (15.43 lb)) and front passenger side buckle switch is ON, then 7 to 36 kg (15.43 to 79.37 lb) is set OFF: Vacant

2.

PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relays, VSV, actuators and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester with the CAN VIM to the DLC3.

SB


SB–24

SEAT BELT – SEAT BELT WARNING SYSTEM

(b) Turn the ignition switch ON and turn the tester ON. (c) Enter the ACTIVE TEST by following the prompts displayed on the tester screen. Combination Meter Assembly: Item

SB

Test Details

Diagnostic Note

D-BELT REMIND

Front driver seat belt warning light / OFF or ON

-

P-BELT REMIND

Front passenger seat belt warning light / OFF or ON

-


SB–25

SEAT BELT – SEAT BELT WARNING SYSTEM

Driver Side Seat Belt Warning Light does not Operate DESCRIPTION When the ignition switch is ON, the center airbag sensor assembly communicates the status of the front seat inner belt assembly LH to the main body ECU using the CAN communication line. The main body ECU receives signals from the center airbag sensor assembly and transmits them to the combination meter assembly. When the seat belt is unfastened, the combination meter assembly flashes the driver seat belt warning light in the combination meter assembly. When the seat belt is fastened, the combination meter assembly stops flashing the front driver seat belt warning light.

WIRING DIAGRAM

Front Seat Inner Belt Assembly LH

Center Airbag Sensor Assembly

LBE+

LBE-

Combination Meter Assembly

CPU

DBE+ CANH

CANH

CANL

CANL

DBESeat Belt Warning Light (Driver Side) Main Body ECU

CAN Communication Line

CANH CANL

B119959E01

INSPECTION PROCEDURE

1

CHECK SUPPLEMENTAL RESTRAINT SYSTEM (a) Connect the intelligent tester with the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the tester ON.

SB


SB–26

SEAT BELT – SEAT BELT WARNING SYSTEM

(c) Enter the following menus: DIAGNOSIS / SRS AIRBAG/ DTC INFO Result

SB

Result

Proceed to

No SRS DTCs are output

A

SRS DTCs are output

B

B

GO TO SUPPLEMENTAL RESTRAINT SYSTEM

A

2

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (D-BELT REMIND) (a) Connect the intelligent tester with the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / METER / ACTIVE TEST

Combination Meter Assembly Item D-BELT REMIND

Test Details

Diagnostic Note

Front driver seat belt warning light / OFF or ON

-

OK: Front driver seat belt warning light comes on. OK NG REPLACE COMBINATION METER ASSEMBLY

REPLACE MAIN BODY ECU


SEAT BELT â&#x20AC;&#x201C; SEAT BELT WARNING SYSTEM

SBâ&#x20AC;&#x201C;27

Front Passenger Side Seat Belt Warning Light Malfunction DESCRIPTION When the ignition switch is ON and the front passenger seat is occupied, the center airbag sensor assembly communicates the status of the front seat inner belt assembly RH to the main body ECU using the CAN communication line. The main body ECU receives signals from the center airbag sensor assembly and transmits them to the combination meter assembly. When the seat belt is unfastened, the combination meter assembly flashes the front passenger seat belt warning light on the instrument panel finish panel end RH*1 or hazard warning signal switch assembly*2. When the seat belt is fastened, the combination meter assembly stops flashing the front passenger seat belt warning light on the instrument panel finish panel end RH*1 or hazard warning signal switch assembly*2. HINT: *1: Hatchback *2: Sedan

SB


SB–28

SEAT BELT – SEAT BELT WARNING SYSTEM

WIRING DIAGRAM

Occupant Classification ECU

SB

Occupant Classification Sensor (Front LH)

Occupant Classification Sensor (Front RH)

Occupant Classification Sensor (Rear LH)

Front Seat Inner Belt Assembly RH

SVC1

SVC1

SIG1

SIG1

BSW

RBE+

SGD1

SGD1

BGND

RBE-

SVC2

SVC2

SIG2

SIG2

SGD2

SGD2

SVC3

SVC3

SIG3

SIG3

SGD3

SGD3

SVC4

SVC4

SIG4

SIG4

SGD4

SGD4

FSR+

FSR-

FSP+

FSP-

Occupant Classification Sensor (Rear RH)

Main Body ECU

Center Airbag Sensor Assembly

CANH

CANH

CANL

CANL Combination Meter Assembly

GAUGE IG+

PBEW

Front Passenger Seat Belt Warning Light*1 Hazard Warning Signal Switch Assembly (Front Passenger Seat Belt Warning Light)*2

*1: Hatchback *2: Sedan

B143896E02

INSPECTION PROCEDURE

1

CHECK SUPPLEMENTAL RESTRAINT SYSTEM (a) Connect the intelligent tester with the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the tester ON.


SB–29

SEAT BELT – SEAT BELT WARNING SYSTEM

(c) Enter the following menus: DIAGNOSIS / SRS AIRBAG/ DTC INFO Result

B

Result

Proceed to

No DTCs are output

A

DTCs are output

B

GO TO SUPPLEMENTAL RESTRAINT SYSTEM

A

2

CHECK OCCUPANT CLASSIFICATION SYSTEM (a) Connect the intelligent tester with the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / OCCUPANT DETECT / DTC INFO Result Result

B

Proceed to

No DTCs are output

A

DTCs are output

B

GO TO OCCUPANT CLASSIFICATION SYSTEM

A

3

READ VALUE OF INTELLIGENT TESTER (P BUCKLE SW) (a) Connect the intelligent tester with the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / SRS AIRBAG/ DATA LIST

Center Airbag Sensor Assembly Item

Measurement Item / Display (Range)

Normal Condition

Diagnostic Note

P BUCKLE SW

Buckle switch (Front passenger side)/ UNSET: Front passenger side seat belt is unfastened SET: Front passenger side seat belt is fastened NG: Front passenger side seat belt is malfunctioning

UNSET/SET

-

OK: Front seat inner belt assembly RH operates normally. OK

Go to step 7

SB


SB–30

SEAT BELT – SEAT BELT WARNING SYSTEM

NG

4

CHECK FRONT SEAT INNER BELT ASSEMBLY RH

Component Side:

SB

Front Seat Inner Belt Assembly RH

RBE+

(a) Disconnect the J11 front seat inner belt assembly RH connector. (b) Measure the resistance. Standard resistance Tester Connection

Condition

Specified Condition

1 (RBE-) - 2 (RBE+)

Tongue plate fastened

10 kΩ or higher

1 (RBE-) - 2 (RBE+)

Tongue plate unfastened

Below 1 Ω

RBE-

(c) Reconnect the front seat inner belt assembly RH connector. NG

REPLACE FRONT SEAT INNER BELT ASSEMBLY RH

B118133E01

OK

5

CHECK HARNESS AND CONNECTOR (ECU - FRONT SEAT INNER BELT ASSEMBLY RH)

Wire Harness Side: Front Seat Inner Belt Assembly RH Connector

(a) Disconnect the J24 occupant classification ECU connector. (b) Disconnect the J11 front seat inner belt assembly RH connector. (c) Measure the resistance. Standard resistance

RBE+

RBEJ11

Front View Occupant Classification ECU Connector

Tester Connection

Specified Condition

J24-9 (BSW) - J11-2 (RBE+)

Below 1 Ω

J24-9 (BSW) or J11-2 (RBE+) - Body ground

10 kΩ or higher

J24-5 (BGND) - J11-1 (RBE-)

Below 1 Ω

J24-5 (BGND) or J11-1 (RBE-) - Body ground

10 kΩ or higher

(d) Reconnect the occupant classification ECU connector. (e) Reconnect the front seat inner belt assembly connector. NG

BGND

BSW J24

Front View B148427E01

REPAIR OR REPLACE HARNESS OR CONNECTOR


SB–31

SEAT BELT – SEAT BELT WARNING SYSTEM

OK

6

CHECK HARNESS AND CONNECTOR (CENTER AIRBAG SENSOR ASSEMBLY OCCUPANT CLASSIFICATION ECU)

Wire Harness Side: Center Airbag Sensor Assembly Connector

J9 5 4 3 2 1

FSP-

10 9 8 7 6

FSP+

15 14 13 12 11

Occupant Classification ECU Connector

FSR-

FSR+ J24

(a) Disconnect the J9 center airbag sensor assembly connector. (b) Disconnect the J24 occupant classification ECU connector. (c) Measure the resistance. Standard resistance Tester Connection

Specified Condition

J9-12 (FSP+) - J24-8 (FSR+)

Below 1 Ω

J9-12 (FSP+) or J24-8 (FSR+) - Body ground

10 kΩ or higher

J9-13 (FSP-) - J24-4 (FSR-)

Below 1 Ω

J9-13 (FSP-) or J24-4 (FSR-) - Body ground

10 kΩ or higher

(d) Reconnect the center airbag sensor assembly connector. (e) Reconnect the occupant classification ECU connector. NG

Front View

REPAIR OR REPLACE HARNESS OR CONNECTOR

B148428E01

OK REPLACE OCCUPANT CLASSIFICATION ECU

7

PERFORM ACTIVE TEST BY INTELLIGENT TESTER (P-BELT REMIND) (a) Connect the intelligent tester with the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / METER / ACTIVE TEST

Combination Meter Assembly Item P-BELT REMIND

Test Details Front passenger seat belt warning light / OFF or ON

Diagnostic Note -

OK: Front passenger seat belt warning light comes on. NG OK

REPLACE COMBINATION METER ASSEMBLY

SB


SB–32

8

SEAT BELT – SEAT BELT WARNING SYSTEM

INSPECT FUSE (GAUGE) (a) Remove the GAUGE fuse from the main body ECU. (b) Measure the resistance. Standard resistance: Below 1 Ω (c) Reinstall the GAUGE fuse.

SB

NG

REPLACE FUSE

OK

9

INSPECT FRONT PASSENGER SEAT BELT WARNING LIGHT

Component Side: Front Passenger Seat Belt Warning Light

(a) Hatchback: (1) Remove the front passenger seat belt warning light. (2) Apply battery voltage to the terminals and check that the indicator illuminates. Standard Tester Connection

Specified Condition

Positive battery - Terminal 6 (IG+) Negative battery - Terminal 3 (PBEW)

Illuminates

(3) Reinstall the front passenger seat belt warning light.

Battery

B128414E02

Component Side: Hazard Warning Signal Switch Assembly (Front Passenger Seat Belt Warning Light)

(b) Sedan: (1) Remove the hazard warning signal switch assembly. (2) Apply battery voltage to the terminals and check that the indicator illuminates. Standard Tester Connection

Specified Condition

Positive battery - Terminal 6 (IG+) Negative battery - Terminal 8 (PBEW)

Illuminates

(3) Reinstall the hazard warning signal switch assembly. NG

Battery B143890E01

OK

REPLACE FRONT PASSENGER SEAT BELT WARNING LIGHT


SB–33

SEAT BELT – SEAT BELT WARNING SYSTEM

10

CHECK HARNESS AND CONNECTOR (FUSE - FRONT PASSENGER SEAT BELT WARNING LIGHT) (a) Hatchback: (1) Disconnect the D27 front passenger seat belt warning light connector. (2) Disconnect the 4S main body ECU connector. (3) Measure the resistance. Standard resistance

Wire Harness Side: Main Body ECU Connector 4S

Front View Front Passenger Seat Belt Warning Light Connector

Tester Connection

Specified Condition

4S-15 - D27-6 (IG+)

Below 1 Ω

4S-15 or D27-6 (IG+) - Body ground

10 kΩ or higher

(4) Reconnect the front passenger seat belt warning light connector. (5) Reconnect the main body ECU connector.

IG+ D27 Front View B143886E01

(b) Sedan: (1) Disconnect the D77 hazard warning signal switch assembly connector. (2) Disconnect the 4S main body ECU connector. (3) Measure the resistance. Standard resistance

Wire Harness Side: Main Body ECU Connector 4S

Tester Connection

Front View Hazard Warning Signal Switch Assembly Connector (Front Passenger Seat Belt Warning Light)

4S-15 - D77-6 (IG+)

Below 1 Ω

4S-15 or D77-6 (IG+) - Body ground

10 kΩ or higher

(4) Reconnect the hazard warning signal switch assembly connector. (5) Reconnect the main body ECU connector. NG

D77

IG+ Front View

B143887E01

OK

Specified Condition

REPAIR OR REPLACE HARNESS OR CONNECTOR

SB


SB–34

11

SEAT BELT – SEAT BELT WARNING SYSTEM

CHECK HARNESS AND CONNECTOR (SEAT BELT WARNING LIGHT - COMBINATION METER ASSEMBLY)

Wire Harness Side:

SB

Front Passenger Seat Belt Warning Light Connector PBEW D27

(a) Hatchback: (1) Disconnect the D2 combination meter assembly connector. (2) Disconnect the D27 front passenger seat belt warning light connector. (3) Measure the resistance. Standard resistance Tester Connection

Front View Combination Meter Assembly Connector D2

Specified Condition

D2-9 - D27-3 (PBEW)

Below 1 Ω

D2-9 or D27-3 (PBEW) - Body ground

10 kΩ or higher

(4) Reconnect the combination meter assembly connector. (5) Reconnect the front passenger seat belt warning light connector.

Front View B147604E01

Wire Harness Side: Hazard Warning Signal Switch Assembly Connector (Front Passenger Seat Belt Warning Light)

PBEW

(b) Sedan: (1) Disconnect the D76 combination meter assembly connector. (2) Disconnect the D77 hazard warning signal switch assembly connector. (3) Measure the resistance. Standard resistance Tester Connection

Specified Condition

D76-9 - D77-8 (PBEW)

Below 1 Ω

D76-9 or D77-8 (PBEW) - Body ground

10 kΩ or higher

D77 Front View

Combination Meter Assembly Connector D76

(4) Reconnect the combination meter assembly connector. (5) Reconnect the hazard warning signal switch assembly connector. NG

Front View B147605E01

OK REPLACE MAIN BODY ECU

REPAIR OR REPLACE HARNESS OR CONNECTOR


SB–32

SEAT BELT ��� FRONT SEAT INNER BELT ASSEMBLY (for Sedan)

FRONT SEAT INNER BELT ASSEMBLY (for Sedan) SEAT BELT RESTRAINTS

COMPONENTS FRONT SEAT INNER BELT ASSEMBLY

FRONT SEAT HEADREST ASSEMBLY

SB 42 (430, 31)

37 (375, 27)

FRONT SEAT ASSEMBLY

x4

BUCKLE SWITCH CONNECTOR

w/ Front Seat Side Airbag: BUCKLE SWITCH CONNECTOR

AIRBAG CONNECTOR

N*m (kgf*cm, ft*lbf) : Specified torque B138568E01


SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Sedan)

SB–33

REMOVAL CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (w/ Front Seat Side Airbag) (See page RS-1). NOTICE: Always use "Torx" socket wrench E10 when removing the front seat. HINT: The procedure described below is for the driver side. Use the same procedure for both the front passenger and driver sides, unless otherwise specified.

B138569

1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working (w/ Front Seat Side Airbag).

2.

REMOVE FRONT SEAT HEADREST ASSEMBLY (See page SE-5)

3.

REMOVE FRONT SEAT ASSEMBLY (See page SE-5)

4.

REMOVE FRONT SEAT INNER BELT ASSEMBLY (a) for Driver Side: (1) Disconnect the seat position sensor connector. (2) Using a clip remover, remove the connector. (3) Using a clip remover, remove the clamp. (4) Remove the clamp.

SB


SB–34

SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Sedan)

(b) for Front Passenger Seat: (1) Using a clip remover, remove the connector. (2) Using a clip remover, remove the clamp. (3) Remove the clamp.

SB

B138570

(c) Remove the wire harness from the claw of the front seat cushion inner shield. (d) Remove the nut and the front seat inner belt.

B138351

INSPECTION 1.

Release

INSPECT FRONT SEAT INNER BELT ASSEMBLY (a) for Driver Side: (1) Check the resistance. 1. Using an ohmmeter, measure the resistance between the terminals. Standard resistance Tester Connection 3-4

Fasten

Condition

Specified Condition

Tongue plate fastened

10 kΩ or higher

Tongue plate released

Below 1 Ω

If the result is not as specified, replace the front seat inner belt.

Ohmmeter B114760E01


SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Sedan)

SB–35

(b) for Front Passenger Side: (1) Check the resistance. 1. Using an ohmmeter, measure the resistance between the terminals. Standard resistance Tester Connection

Release

Fasten

Ohmmeter B114761E01

1-2

Condition

Specified Condition

Tongue plate fastened

10 kΩ or higher

Tongue plate released

Below 1 Ω

If the result is not as specified, replace the front seat inner belt.

SB


SB–36

SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Sedan)

INSTALLATION CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary concerning the SRS airbag system before servicing (w/ Front Seat Side Airbag) (See page RS-1). NOTICE: Always use "Torx" socket wrench E10 when installing the front seat. HINT: The procedure described below is for the driver side. Use the same procedure for both the front passenger and drive sides, unless otherwise specified.

SB

1.

Convex

INSTALL FRONT SEAT INNER BELT ASSEMBLY (a) Install the front seat inner belt with the nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: Do not place the front seat inner belt over the convex areas of the front seat adjuster frame. (b) Install the wire harness into the claw of the front seat cushion inner shield.

B138352E01

(c) for Driver Side: (1) Install the 2 clamps. (2) Install the connector. (3) Connect the seat position sensor connector.

B138569


SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Sedan)

SB–37

(d) for Front Passenger Side: (1) Install the 2 clamps. (2) Install the connector.

B138570

2.

INSTALL FRONT SEAT ASSEMBLY (See page SE-20)

3.

INSTALL FRONT SEAT HEADREST ASSEMBLY (See page SE-21)

4.

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

5.

INSPECT SRS WARNING LIGHT (w/ Front Seat Side Airbag) (See page RS-31)

SB


SB–37

SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Hatchback)

FRONT SEAT INNER BELT ASSEMBLY (for Hatchback) SEAT BELT RESTRAINTS

COMPONENTS for Driver Side:

SB

FRONT SEAT HEADREST ASSEMBLY 42 (430, 31)

FRONT SEAT INNER BELT ASSEMBLY

FRONT SEAT ASSEMBLY 37 (375, 27)

x4

BUCKLE SWITCH CONNECTOR

w/ Front Seat Side Airbag: BUCKLE SWITCH CONNECTOR

AIRBAG CONNECTOR

N*m (kgf*cm, ft*lbf) : Specified torque B114721E01


SB–38

SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Hatchback)

for Front Passenger Side: FRONT SEAT HEADREST ASSEMBLY

SB

FRONT SEAT ASSEMBLY

37 (375, 27)

x4

OCCUPANT DETECTION SENSOR CONNECTOR

BUCKLE SWITCH CONNECTOR FRONT SEAT INNER BELT ASSEMBLY

42 (430, 31)

w/ Front Seat Side Airbag: BUCKLE SWITCH CONNECTOR AIRBAG CONNECTOR

OCCUPANT DETECTION SENSOR CONNECTOR

N*m (kgf*cm, ft*lbf) : Specified torque B114722E01


SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Hatchback)

SB–39

REMOVAL CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (w/ Front Seat Side Airbag) (See pageRS-1). NOTICE: Always use "Torx" socket wrench E10 when removing the front seat. HINT: The procedure described below is for the driver side. Use the same procedure for both the driver and front passenger sides, unless otherwise specified. 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working (w/ Front Seat Side Airbag).

2.

REMOVE FRONT SEAT HEADREST ASSEMBLY (See page SE-28)

3.

REMOVE FRONT SEAT ASSEMBLY (See page SE-28)

4.

REMOVE FRONT SEAT INNER BELT ASSEMBLY (a) for Driver Side: (1) Disconnect the seat position sensor connector. (2) Remove the buckle switch connector. (3) Remove the 2 wiring harness clamps.

B114765

(4) Remove the wire harness from the claw of the front seat cushion shield. (5) Remove the bolt and the front seat inner belt.

B114766

SB


SB–40

SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Hatchback)

(b) for Front Passenger Side: (1) Remove the buckle switch connector. (2) Remove the 2 wiring harness clamps.

SB B114764

(3) Remove the wiring harness from the claw of the front seat cushion shield. (4) Remove the bolt and the front seat inner belt.

B114762

INSPECTION 1.

Release

INSPECT FRONT SEAT INNER BELT ASSEMBLY (a) for Driver Side: (1) Check the resistance. 1. Using an ohmmeter, measure the resistance between the terminals. Standard resistance Tester Connection 3-4

Fasten

Condition

Specified Condition

Tongue plate fastened

10 kΩ or higher

Tongue plate released

Below 1 Ω

If the result is not as specified, replace the front seat inner belt.

Ohmmeter B114760E01


SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Hatchback)

SB–41

(b) for Front Passenger Side: (1) Check the resistance. 1. Using an ohmmeter, measure the resistance between the terminals. Standard resistance Tester Connection

Release

Fasten

Ohmmeter B114761E01

1-2

Condition

Specified Condition

Tongue plate fastened

10 kΩ or higher

Tongue plate released

Below 1 Ω

If the result is not as specified, replace the front seat inner belt.

SB


SB–42

SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Hatchback)

INSTALLATION CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (w/ Front Seat Side Airbag) (See pageRS-1). NOTICE: Always use "Torx" socket wrench E10 when installing the front seat. HINT: The procedure described below is for the driver side. Use the same procedure for both the driver and front passenger sides, unless otherwise specified.

SB

1.

Convex B114767E01

INSTALL FRONT SEAT INNER BELT ASSEMBLY (a) for Driver Side: (1) Install the front seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: Do not place the front seat inner belt over the convex areas of the front seat adjuster frame. (2) Install the wire harness into the claw of the front seat cushion shield. (3) Install the 2 wiring harness clamps. (4) Install the buckle switch connector. (5) Connect the seat position sensor connector.

B114765

Convex

B114763E01

(b) for Front Passenger Side: (1) Install the front seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: Do not place the front seat inner belt over the convex areas of the front seat adjuster frame. (2) Install the wiring harness onto the claw of the front seat cushion shield.


SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (for Hatchback)

SB–43

(3) Install the 2 wiring harness clamps. (4) Install the buckle switch connector. 2.

INSTALL FRONT SEAT ASSEMBLY (See page SE-42)

3.

INSTALL FRONT SEAT HEADREST ASSEMBLY (See page SE-43)

4.

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

B114764

5.

INSPECT SRS WARNING LIGHT (w/ Front Seat Side Airbag) (See page RS-31)

SB


SB–43

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

FRONT SEAT OUTER BELT ASSEMBLY (for Sedan) SEAT BELT RESTRAINTS

COMPONENTS FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY

42 (430, 31)

SB CENTER PILLAR UPPER GARNISH

x2

SHOULDER BELT ANCHORAGE PLATE COVER

REAR DOOR OPENING TRIM WEATHERSTRIP

FRONT DOOR OPENING TRIM WEATHERSTRIP

42 (430, 31)

4.9 (50, 43 in.*lbf)

SEAT BELT ANCHOR COVER CAP

42 (430, 31)

CENTER PILLAR LOWER GARNISH

FRONT DOOR SCUFF PLATE

PRETENSIONER CONNECTOR

REAR DOOR SCUFF PLATE

FRONT SEAT OUTER BELT ASSEMBLY

LAP BELT OUTER ANCHOR COVER 42 (430, 31)

N*m (kgf*cm, ft.*lbf) : Specified torque B134890E01


SB–44

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

REMOVAL CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (See page RS-1). HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified.

SB

1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working.

2.

REMOVE FRONT DOOR SCUFF PLATE (See page IR14)

3.

REMOVE REAR DOOR SCUFF PLATE (See page IR15)

4.

REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP (a) Remove the front door opening trim weatherstrip to the extent that the center pillar upper and lower garnishes can be removed.

5.

REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP (a) Remove the rear door opening trim weatherstrip to the extent that the center pillar upper and lower garnishes can be removed.

6.

REMOVE CENTER PILLAR LOWER GARNISH (See page IR-16)

7.

REMOVE SEAT BELT ANCHOR COVER CAP (a) Pull portion A, shown in the illustration, toward you, remove the 2 claws on the lower side followed by the claw on the upper side. Then remove the seat belt anchor cover cap.

B138445

B138446

A B114421E01


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

8.

SB–45

REMOVE LAP BELT OUTER ANCHOR COVER (a) Disengage the 3 claws and remove the lap belt outer anchor cover.

SB B134891

9.

REMOVE FRONT SEAT OUTER BELT ASSEMBLY (a) Remove the bolt and the anchor plate.

B134892

(b) Remove the bolt and the shoulder anchor.

B114296

(c) Disconnect the pretensioner connector. (1) Using a screwdriver, release the locking button. (2) Using a screwdriver, disconnect the pretensioner connector.

Locking Button

B134893E01


SB–46

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

(d) Remove the 2 bolts, the 2 hooks and the retractor. 10. REMOVE CENTER PILLAR UPPER GARNISH (See page IR-17)

SB B134896

11. REMOVE SHOULDER BELT ANCHORAGE PLATE COVER (a) Disengage the 2 claws and remove the shoulder belt anchorage plate cover.

B134897

12. REMOVE FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Remove the 2 bolts, the hook and the front shoulder belt anchor adjuster.

B134898


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–47

INSTALLATION CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (See page RS-1). HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

INSTALL FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Insert the hook into the body hole and install the shoulder belt anchor adjuster with the 2 bolts. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

2.

INSTALL SHOULDER BELT ANCHORAGE PLATE COVER (a) Engage the 2 claws and install the shoulder belt anchorage plate cover.

3.

INSTALL CENTER PILLAR UPPER GARNISH (See page IR-31)

4.

INSTALL FRONT SEAT OUTER BELT ASSEMBLY (a) Check the angle of inclination required to lock the retractor. (1) Gently incline the retractor from its initial position. Check that the belt does not lock when the retractor is inclined 15 ° or less in any direction. Also, check that the belt locks when the inclination of the retractor is 45 ° or more. NOTICE: Do not disassemble the retractor. If the operation is not as specified, replace the front seat outer belt.

B134898

B134897

Unlock 45° Lock

B114426E01

(b) Hook the lower stay of the retractor onto the 2 body hooks and provisionally install the retractor with the 2 bolts. (c) Tighten bolt A and then bolt B. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) for bolt A 42 N*m (430 kgf*cm, 31 ft.*lbf) for bolt B

A

B

B134896E01

SB


SB–48

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

(d) Connect the pretensioner connector. (1) Connect the pretensioner connector. (2) Lock the locking button. NOTICE: Securely lock the locking button.

SB

Lock Button B134894E01

(e) Install the shoulder anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

B114296

(f)

B134892

Install the anchor plate with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (g) Check that the ELR locks. NOTICE: • The check should be performed with the front seat outer belt installed. • Do not allow the anchor part of the front seat outer belt and the protruding parts of the floor panel to overlap. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the front seat outer belt.


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

5.

SB–49

INSTALL LAP BELT OUTER ANCHOR COVER (a) Engage the 3 claws and install the lap belt outer anchor cover.

SB B134891

6.

INSTALL SEAT BELT ANCHOR COVER CAP (a) Engage the 3 claws and install the seat belt anchor cover cap.

7.

INSTALL CENTER PILLAR LOWER GARNISH (See page IR-32)

8.

INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP (a) Install the rear door opening trim weatherstrip.

9.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP (a) Install the front door opening trim weatherstrip.

B114428

B138446

10. INSTALL REAR DOOR SCUFF PLATE (See page IR34) 11. INSTALL FRONT DOOR SCUFF PLATE (See page IR35) B138445

12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 13. INSPECT SRS WARNING LIGHT (See page RS-31)


SB–50

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

DISPOSAL CAUTION: • Never dispose of a front seat outer belt that has an inactivated pretensioner. • The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the operation outside and where it will not be a nuisance to persons nearby. • When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (33 ft) away from the front seat outer belt. • Use gloves and safety glasses when handling a front seat outer belt with an activated pretensioner. • Always wash your hands with water after completing the activation. • Do not apply water to a front seat outer belt that has an activated pretensioner. • When activating the seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). • Perform the operation in a place away from electrical interference. HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified.

SB

1.

DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (When Installed in Vehicle) HINT: Prepare a battery as the power source to activate the seat belt pretensioner. (a) Check whether SST is functioning. SST 09082-00700 CAUTION: Always use the specified SST when activating the seat belt pretensioner.

SST

B104819E01

Battery

SST B104820E01

(1) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. HINT: Do not connect the yellow connector. The yellow connector is for connections to the seat belt pretensioner.


SEAT BELT â&#x20AC;&#x201C; FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

SST B104821E01

SBâ&#x20AC;&#x201C;51

(2) Press the SST activation switch and check that the LED of the SST activation switch turns on. CAUTION: If the LED illuminates when the activation switch is not being pressed, SST may be malfunctioning. Do not use SST. (b) Disconnect SST from the battery. (c) Disconnect the pretensioner connector. (1) Disconnect the cable from the negative battery terminal. (2) Remove the front door scuff plate (See page IR-14). (3) Remove the rear door scuff plate (See page IR15). (4) Remove the front door opening trim weatherstrip. 1. Remove the front door opening trim weatherstrip to the extent that the center pillar lower garnish can be removed.

B138447

(5) Remove the rear door opening trim weatherstrip. 1. Remove the rear door opening trim weatherstrip to the extent that the center pillar lower garnish can be removed. (6) Remove the center pillar lower garnish (See page IR-16).

B138448

SB


SB–52

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

(7) Disconnect the pretensioner connector. 1. Using a screwdriver, release the locking button. 2. Using a screwdriver, disconnect the pretensioner connector.

SB

Locking Button

B134893E01

(d) Connect SST. (1) Connect SST, then the yellow connector to the seat belt pretensioner. SST 09082-00770 NOTICE: Do not lock the secondary lock of the twin lock to avoid damaging the SST connector and wire harness. SST

Locking Button B134895E01


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–53

(2) Move SST at least 10 m (33 ft) away from the front of the vehicle. SST 09082-00700 (3) Close the doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. HINT: Do not close the windows fully. Leave a gap for inserting the SST wire harness. (4) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. (e) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) of the vehicle. (2) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the SST activation switch LED light. (f) Disconnect SST. (g) Dispose of the front seat outer belt (with the seat belt pretensioner). HINT: When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with the activated front seat outer belt still installed. CAUTION: • Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. • Use gloves and safety glasses when handling a front seat outer belt with a pretensioner that has been activated. • Always wash your hands with water after completing the operation. • Do not apply water to a front seat outer belt that has an activated pretensioner.

Battery 10 m (33 ft)

SST B134899E01

2.

DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (When not Installed in Vehicle) HINT: Prepare a battery as the power source to activate the seat belt pretensioner. NOTICE: • When only disposing of the front seat outer belt (with the seat belt pretensioner), never use the customer's vehicle to activate the seat belt pretensioner. • Be sure to follow the procedures described below when activating the seat belt pretensioner. (a) Remove the front seat outer belt (See page SB-44).

SB


SB–54

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

(b) Wind the seat belt with the retractor. (c) When the seat belt is sufficiently wound, cut the seat belt approximately 10 cm (0.328 ft) from the retractor, as shown in the illustration. HINT: The retractor resistance increases in correlation with how much the seat belt is wound.

Cut

10 cm (0.328 ft)

SB B114471E01

(d) Check whether SST is functioning. SST 09082-00700 CAUTION: Always use the specified SST when activating the seat belt pretensioner.

SST

B104819E01

Battery

(1) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. HINT: Do not connect the yellow connector. The yellow connector is for connections to the seat belt pretensioner.

SST B104820E01

(2) Press the SST activation switch and check that the LED of the SST activation switch turns on. CAUTION: If the LED illuminates when the activation switch is not being pressed, SST may be malfunctioning. Do not use SST.

SST B104821E01


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–55

(e) Connect SST. (1) Connect SST, then the yellow connector to the seat belt pretensioner. SST 09082-00770 NOTICE: Do not lock the secondary lock of the twin lock to avoid damaging the SST connector and wire harness. SST

Locking Button B114472E01

(2) Using a service-purpose wire harness for the vehicle, tie the seat belt pretensioner to the tire with a wheel attached. Stripped wire harness section A

Area A

Stripped Wire Harness Section B104882E01

Measurement 2

1.25 mm or more (0.0019 in2 or more)

CAUTION: • Do not use wire harnesses that are too thin or any other object to tie the seat belt pretensioner because they may snap due to the shock when the pretensioner is deployed. • Always use a wire harness for vehicle use, with a cross section of at least 1.25 mm2 (0.0019 in2). HINT: To calculate the area of the stripped wire harness cross section: Area = 3.14 x (Diameter)2 divided by 4

SB


SB–56

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

(3) Connect SST. SST 09082-00700 NOTICE: • Do not lock the secondary lock of the twin lock to avoid damaging the SST connector and wire harness. • Set up the front seat outer belt, as shown in the illustration.

SST

SB

Wire Harness

B114473E01

Battery

10 m (33 ft)

(4) Move SST at least 10 m (33 ft) away from the wheel. NOTICE: Take care not to damage the SST wire harness. (f) Activate the seat belt pretensioner. (1) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. (2) Check that no one is within 10 m (33 ft) of the wheel. (3) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the SST activation switch LED light. (g) Disconnect SST.

SST B114550E01

Plastic Bag

B114475E01

(h) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: • Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. • Use gloves and safety glasses when handling an front seat outer belt with a pretensioner that has been activated. • Always wash your hands with water after completing the operation. • Do not apply water to a front seat outer belt that has an activated pretensioner.


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–57

(1) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts.

SB


SB–58

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door) SEAT BELT RESTRAINTS

COMPONENTS

SB

FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY

x2

42 (430, 31)

CENTER PILLAR UPPER GARNISH

REAR DOOR OPENING TRIM WEATHERSTRIP

SHOULDER BELT ANCHOR COVER

42 (430, 31)

FRONT DOOR OPENING TRIM WEATHERSTRIP

4.9 (50, 43 in.*lbf)

SEAT BELT ANCHOR COVER CAP

REAR DOOR SCUFF PLATE

42 (430, 31)

FRONT SEAT OUTER BELT ASSEMBLY FRONT DOOR SCUFF PLATE

PRETENSIONER CONNECTOR

CENTER PILLAR LOWER GARNISH

42 (430, 31)

N*m (kgf*cm, ft*lbf) : Specified torque B114418E01


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–59

REMOVAL CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (See page RS-1). HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working.

2.

REMOVE FRONT DOOR SCUFF PLATE (See page IR49)

3.

REMOVE REAR DOOR SCUFF PLATE (See page IR51)

4.

REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP (a) Remove the front door opening trim weatherstrip to the extent that the center pillar upper and lower garnishes can be removed.

5.

REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP (a) Remove the rear door opening trim weatherstrip to the extent that the center pillar upper and lower garnishes can be removed.

6.

REMOVE CENTER PILLAR LOWER GARNISH (See page IR-55)

7.

REMOVE SEAT BELT ANCHOR COVER CAP (a) Pull portion A, shown in the illustration, toward you, remove the 2 claws on the lower side followed by the claw on the upper side. Then remove the seat belt anchor cover cap.

B114419

B114420

A B114421E01

SB


SB–60

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

8.

REMOVE FRONT SEAT OUTER BELT ASSEMBLY (a) Remove the anchor plate cover.

SB B114294

(b) Remove the bolt and the anchor plate.

B114295

(c) Remove the bolt and the through anchor.

B114296

(d) Disconnect the pretensioner connector. (1) Using a screwdriver, release the locking button. (2) Using a screwdriver, disconnect the pretensioner connector.

Locking Button

B114422E01


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–61

(e) Remove the 2 bolts, the 2 hooks and the retractor. 9.

REMOVE CENTER PILLAR UPPER GARNISH (See page IR-55)

SB B114423

10. REMOVE SHOULDER BELT ANCHOR COVER (a) Disengage the 2 claws and remove the shoulder belt anchor cover.

B114424

11. REMOVE FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Remove the 2 bolts, the hook and the front shoulder belt anchor adjuster.

B114425


SB–62

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

INSTALLATION CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (See page RS-1). HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified.

SB

1.

INSTALL FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Insert the hook into the body hole and install the shoulder belt anchor adjuster with the 2 bolts. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

2.

INSTALL SHOULDER BELT ANCHOR COVER (a) Engage the 2 claws and install the shoulder belt anchor cover.

3.

INSTALL CENTER PILLAR UPPER GARNISH (See page IR-76)

4.

INSTALL FRONT SEAT OUTER BELT ASSEMBLY (a) Check the angle of inclination required to lock the retractor. (1) Gently incline the retractor from its initial position. Check that the belt does not lock when the retractor is inclined 15° or less in any direction. Also, check that the belt locks when the inclination of the retractor is 45° or more. NOTICE: Do not disassemble the retractor. If the operation is not as specified, replace the front seat outer belt.

B114425

B114424

Unlock 45° Lock

B114426E01

(b) Hook the lower stay of the retractor onto the 2 body hooks and provisionally install the retractor with the 2 bolts. (c) Tighten bolt A and then bolt B. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) for bolt A 42 N*m (430 kgf*cm, 31 ft.*lbf) for bolt B

A

B

B114423E01


SEAT BELT â&#x20AC;&#x201C; FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

B114296

(d) Install the through anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (e) Check that the ELR locks. NOTICE: Perform the check with the front seat outer belt installed. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the front seat outer belt. (f)

Connect the pretensioner connector. (1) Connect the pretensioner connector. (2) Lock the locking button. NOTICE: Securely lock the locking button.

Locking Button B114427E01

(g) Install the anchor plate with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

B114295

(h) Install the anchor plate cover.

B114294

SBâ&#x20AC;&#x201C;63

SB


SB–64

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

5.

INSTALL SEAT BELT ANCHOR COVER CAP (a) Engage the 3 claws and install the seat belt anchor cover cap.

6.

INSTALL CENTER PILLAR LOWER GARNISH (See page IR-76)

7.

INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP (a) Install the rear door opening trim weatherstrip.

8.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP (a) Install the front door opening trim weatherstrip.

9.

INSTALL REAR DOOR SCUFF PLATE (See page IR80)

SB B114428

B114420

10. INSTALL FRONT DOOR SCUFF PLATE (See page IR82) B114419

11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 12. INSPECT SRS WARNING LIGHT (See page RS-31)


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–65

DISPOSAL CAUTION: • Never dispose of a front seat outer belt that has an inactivated pretensioner. • The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the operation outside and where it will not be a nuisance to persons nearby. • Stand at least 10 m (33 ft) away when activating a front seat outer belt (with seat belt pretensioner). • Use gloves and safety glasses when handling a front seat outer belt with an activated pretensioner. • Always wash your hands with water after completing an activation. • Do not apply water to a front seat outer belt that has an activated pretensioner. • Always use the specified SST (SRS airbag deployment tool) when activating the seat belt pretensioner. • Perform the operation in a place away from electrical interference. HINT: The procedure described below is for the RH side. Use the same procedure for the RH and LH sides, unless otherwise specified. 1.

DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (When Installed in Vehicle) HINT: Prepare a battery as the power source to activate the seat belt pretensioner. (a) Check whether SST is functioning. SST 09082-00700 CAUTION: Always use the specified SST when activating the seat belt pretensioner.

SST

B104819E01

Battery

SST B104820E01

(1) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. HINT: Do not connect the yellow connector. The yellow connector is for connections to the seat belt pretensioner.

SB


SBâ&#x20AC;&#x201C;66

SB

SEAT BELT â&#x20AC;&#x201C; FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SST B104821E01

(2) Press the SST activation switch and check that the LED of the SST activation switch turns on. CAUTION: If the LED turns on when the activation switch is not being pressed, SST may be malfunctioning. Do not use SST. (b) Disconnect SST from the battery. (c) Disconnect the pretensioner connector. (1) Disconnect the cable from negative battery terminal. (2) Remove the front door scuff plate (See page IR-49). (3) Remove the rear door scuff plate (See page IR51). (4) Remove the front door opening trim weatherstrip. 1. Remove the front door opening trim weatherstrip to the extent that the center pillar lower garnish can be removed.

B119867

(5) Remove the rear door opening trim weatherstrip. 1. Remove the rear door opening trim weatherstrip to the extent that the center pillar lower garnish can be removed. (6) Remove the center pillar lower garnish (See page IR-55 ).

B119869


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–67

(7) Disconnect the pretensioner connector as shown in the illustration.

SB Locking Button

B114422E01

(d) Connect SST. (1) Connect SST, then connect the yellow connector to the seat belt pretensioner. SST 09082-00770 NOTICE: Do not lock the secondary lock of the twin lock to avoid damaging the SST connector and wire harness SST

Locking Button

B114456E01


SB–68

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

(2) Move SST at least 10 m (33 ft) away from the front of the vehicle. SST 09082-00700 (3) Close the doors and windows of the vehicle. HINT: Do not close the windows fully. Leave a gap for inserting the SST wire harness. NOTICE: Do not damaging the SST wire harness. (4) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. (e) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) of the vehicle. (2) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the SST activation switch LED light. (f) Disconnect SST. (g) Dispose of the front seat outer belt (with the seat belt pretensioner). HINT: When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with the activated front seat outer belt still installed. CAUTION: • Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. • Use gloves and safety glasses when handling a front seat outer belt with a pretensioner that has been activated. • Always wash your hands with water after completing the operation. • Do not apply water to a front seat outer belt that has an activated pretensioner.

SB

Battery 10 m (33 ft)

SST B114470E01

2.

DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (When not Installed in Vehicle) HINT: Prepare a battery as the power source to activate the seat belt pretensioner. NOTICE: • When only disposing of the front seat outer belt (with the seat belt pretensioner), never use the customer's vehicle to activate the seat belt pretensioner. • Follow the procedure described below when activating the seat belt pretensioner. (a) Remove the front seat outer belt assembly (See page SB-59).


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

(b) Wind the seat belt with the retractor. (c) When the seat belt is sufficiently wound, cut the seat belt approximately 10 cm (0.328 ft) from the retractor, as shown in the illustration. HINT: The retractor resistance increases in correlation with how much the seat belt is wound.

Cut

10 cm (0.328 ft)

SB–69

SB B114471E01

(d) Check whether SST is functioning. SST 09082-00700 CAUTION: Always use the specified SST when activating the seat belt pretensioner.

SST

B104819E01

Battery

(1) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. HINT: Do not connect the yellow connector. The yellow connector is for connections to the seat belt pretensioner.

SST B104820E01

(2) Press the SST activation switch and check that the LED of the SST activation switch turns on. CAUTION: If the LED turns on when the activation switch is not being pressed, SST may be malfunctioning. Do not use SST.

SST B104821E01


SB–70

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

(e) Connect SST. (1) Connect SST, then connect the yellow connector to the seat belt pretensioner. SST 09082-00770 NOTICE: Do not lock the secondary lock of the twin lock to avoid damaging the SST connector and wire harness.

SB SST

Locking Button B114472E01

(2) Using a service-purpose wire harness for the vehicle, tie the seat belt pretensioner to the tire with a wheel attached. Stripped wire harness section: A

Stripped Wire Harness Section B104882E01

Area A

Measurement 1.25

mm2

or more (0.0019 in2 or more)

CAUTION: • Do not use wire harnesses that are too thin or any other object to tie the seat belt pretensioner because they may snap due to the shock when the pretensioner is deployed. • Always use a wire harness for vehicle use, with a cross section of at least 1.25 mm2 (0.0019 in2). HINT: To calculate the area of the stripped wire harness cross section: Area = 3.14 x (Diameter)2 divided by 4


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–71

(3) Connect SST. SST 09082-00700 NOTICE: • Do not lock the secondary lock of the twin lock to avoid damaging the SST connector and wire harness. • Set up the front seat outer belt, as shown in the illustration.

SST Wire Harness

B114473E01

(4) Move SST at least 10 m (33 ft) away from the wheel. NOTICE: Do not damage the SST wire harness. (f) Activate the seat belt pretensioner. (1) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. (2) Check that no one is within 10 m (33 ft) of the wheel. (3) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the SST activation switch LED light. (g) Disconnect SST.

Battery

10 m (33 ft) SST B114550E01

Plastic Bag

B114475E01

(h) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: • Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. • Use gloves and safety glasses when handling a front seat outer belt with a pretensioner that has been activated. • Always wash your hands with water after completing the operation. • Do not apply water to a front seat outer belt that has an activated pretensioner.

SB


SB–72

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

(1) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts.

SB


SB–72

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door) SEAT BELT RESTRAINTS

COMPONENTS

SB

PACKAGE TRAY TRIM PANEL ASSEMBLY

DECK BOARD SUB-ASSEMBLY

DECK FLOOR BOX

DECK FLOOR BOX

B127707E02


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–73

for 60/40 Split Seat Type:

REAR SEAT ASSEMBLY

NO. 1 REAR SEAT LEG COVER

SB

37 (375, 27)

REAR SEAT ASSEMBLY

x6

NO. 2 REAR SEAT LEG COVER

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

x7

for Hold Down Seat Type:

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

REAR SEATBACK ASSEMBLY

37 (375, 27)

x4

N*m (kgf*cm, ft*lbf) : Specified torque B121713E05


SB–74

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB

42 (430, 31)

SEAT BELT ANCHOR COVER CAP 4.9 (50, 43 in.*lbf)

REAR SEAT OUTER BELT ASSEMBLY PRETENSIONER CONNECTOR

42 (430, 31)

FRONT DOOR SCUFF PLATE

FRONT QUARTER TRIM PANEL ASSEMBLY

FRONT SEAT OUTER BELT ASSEMBLY

FRONT DOOR OPENING TRIM WEATHERSTRIP

42 (430, 31)

N*m (kgf*cm, ft*lbf) : Specified torque B138697E01


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–75

REMOVAL CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (See page RS-1). NOTICE: Always use "Torx" socket wrench E10 when removing the rear seat. HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working.

2.

REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-48)

3.

REMOVE DECK BOARD SUB-ASSEMBLY (See page IR-48)

4.

REMOVE DECK FLOOR BOX (a) for RH Side: (1) Remove the deck floor box (See page IR-48). (b) for LH Side: HINT: Use the same procedure as for the RH side.

5.

REMOVE NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH Side: (1) Remove the No. 1 rear seat leg cover (See page SE-89). (b) for LH Side: (1) Remove the No. 1 rear seat leg cover (See page SE-70).

6.

REMOVE NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type LH Side) (See page SE-70)

7.

REMOVE REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (a) for RH Side: (1) Remove the rear seat assembly (See page SE89). (b) for LH Side: (1) Remove the rear seat assembly (See page SE71).

8.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE114)

9.

REMOVE REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-115)

SB


SB–76

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

10. REMOVE FRONT DOOR SCUFF PLATE (See page IR97) 11. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP (a) Remove the front door opening trim weatherstrip to the extent that the front quarter trim panel can be removed.

SB B114477

12. REMOVE REAR SEAT OUTER BELT ASSEMBLY (a) Remove the belt.

B114498

13. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY (a) Disengage the 8 clips, the retainer and the 10 claws and remove the front quarter trim panel.

B114499

14. REMOVE SEAT BELT ANCHOR COVER CAP (a) Disengage the 3 claws and remove the seat belt anchor cover cap.

B114478


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–77

15. REMOVE FRONT SEAT OUTER BELT ASSEMBLY (a) Remove the anchor plate cover.

SB B114496

(b) Remove the bolt and the anchor plate.

B114497

(c) Remove the bolt and the through anchor.

B114479

(d) Disconnect the pretensioner connector. (1) Using a screwdriver, release the locking button. (2) Using a screwdriver, disconnect the pretensioner connector.

Locking Button

B114422E01


SB–78

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

(e) Remove the 2 bolts, the 2 hooks and the retractor.

SB B114423


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–79

INSTALLATION CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (See page RS-1). NOTICE: Always use "Torx" socket wrench E10 when installing the rear seat. HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. Unlock 45° Lock

B114426E01

INSTALL FRONT SEAT OUTER BELT ASSEMBLY (a) Check the angle of inclination required to lock the retractor. (1) Gently incline the retractor from its initial position. Check that the belt does not lock when the retractor is inclined 15° or less in any direction. Also, check that the belt locks when the inclination of the retractor is 45° or more. NOTICE: Do not disassemble the retractor. If the operation is not as specified, replace the front seat outer belt. (b) Hook the lower stay of the retractor onto the 2 body hooks and provisionally install the retractor with the 2 bolts. (c) Tighten bolt A and then bolt B. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) for bolt A 42 N*m (430 kgf*cm, 31 ft.*lbf) for bolt B

A

B

1.

B114423E01

B114479

(d) Install the through anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (e) Check that the ELR locks. NOTICE: Perform the check with the front seat outer belt installed (1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the front seat outer belt.

SB


SB–80

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

(f)

Install the anchor plate with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

SB B114497

(g) Install the anchor plate cover.

B114496

(h) Connect the pretensioner connector. (1) Connect the pretensioner connector. (2) Lock the locking button. NOTICE: Securely lock the locking button.

Locking Button B114427E01

2.

B114478

INSTALL SEAT BELT ANCHOR COVER CAP (a) Engage the 3 claws and install the seat belt anchor cover cap.


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

3.

SB–81

INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY (a) Engage the 8 clips, the retainer and the 10 claws and install the front quarter trim panel.

SB

B114499

4.

INSTALL REAR SEAT OUTER BELT ASSEMBLY (a) Install the belt.

5.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP (a) Install the front door opening trim weatherstrip.

6.

INSTALL FRONT DOOR SCUFF PLATE (See page IR119)

7.

INSTALL REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (a) for RH Side: (1) Install the rear seat assembly (See page SE102). (b) for LH Side: (1) Install the rear seat assembly (See page SE84).

8.

INSTALL NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type LH Side) (See page SE-85)

9.

INSTALL NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH Side: (1) Install the No. 1 rear seat leg cover (See page SE-89). (b) for LH Side: (1) Install the No. 1 rear seat leg cover (See page SE-85).

B114498

B114477

10. INSTALL REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-122)


SB–82

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

11. INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE123)

SB

12. INSTALL DECK FLOOR BOX (a) for RH side: (1) Install the deck floor box (See page IR-83). (b) for LH Side: HINT: Use the same procedure as for the RH side. 13. INSTALL DECK BOARD SUB-ASSEMBLY (See page IR-83) 14. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-83) 15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 16. INSPECT SRS WARNING LIGHT (See page RS-31)


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–83

DISPOSAL CAUTION: • Never dispose of a front seat outer belt that has an inactivated pretensioner. • The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the operation outside and where it will not be a nuisance to persons nearby. • Stand at least 10 m (33 ft) away when activating a front seat outer belt (with seat belt pretensioner). • Use gloves and safety glasses when handling a front seat outer belt with an activated pretensioner. • Always wash your hands with water after completing an activation. • Do not apply water to a front seat outer belt that has an activated pretensioner. • Always use the specified SST (SRS airbag deployment tool) when activating the seat belt pretensioner. • Perform the operation in a place away from electrical interference. NOTICE: Always use "Torx" socket wrench E10 when removing the rear seat. HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (When Installed in Vehicle) HINT: Prepare a battery as the power source to activate the seat belt pretensioner. (a) Check whether SST is functioning. SST 09082-00700 CAUTION: Always use the specified SST when activating the seat belt pretensioner.

SST

B104819E01

Battery

SST B104820E01

(1) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. HINT: Do not connect the yellow connector. The yellow connector is for connections to the seat belt pretensioner.

SB


SB–84

SB

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SST B104821E01

(2) Press the SST activation switch and check that the LED of the SST activation switch turns on. CAUTION: If the LED turns on when the activation switch is not being pressed, SST may be malfunctioning. Do not use SST. (b) Disconnect SST from the battery. (c) Disconnect the pretensioner connector. (1) Disconnect the cable from the negative battery terminal. (2) Remove the package tray trim panel assembly (See page IR-48). (3) Remove the deck board sub-assembly (See page IR-48). (4) Remove the deck floor box RH (See page IR48). (5) Remove the deck floor box LH (for 60/40 Split Seat Type and Bench Seat Type). HINT: Use the same procedure as for the RH side. (6) Remove the rear seat No. 1 leg cover (for 60/ 40 Split Seat Type) (See page SB-75). (7) Remove the rear seat No. 2 leg cover (for 60/ 40 Split Seat Type LH Side) (See page SE-70). (8) Remove the rear seat assembly (for 60/40 Split Seat Type) (See page SB-75). (9) Remove the rear seat cushion cover pad subassembly (for Bench Seat Type) (See page SE114). (10) Remove the rear seatback assembly (for Bench Seat Type) (See pageSE-115). (11) Remove the front door scuff plate (See page IR-97). (12) Remove the front door opening trim weatherstrip (See page SB-76). (13) Remove the rear seat outer belt assembly. 1. Remove the belt.

B114498


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–85

(14) Remove the front quarter trim panel assembly. 1. Disengage the 8 clips, the retainer and the 10 claws and remove the front quarter trim panel.

SB

B114499

(15) Disconnect the pretensioner connector as shown in the illustration.

Locking Button

B114422E01


SBâ&#x20AC;&#x201C;86

SEAT BELT â&#x20AC;&#x201C; FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

(d) Connect SST. (1) Connect SST, then connect the yellow connector to the seat belt pretensioner. SST 09082-00770 NOTICE: Do not lock the secondary lock of the twin lock to avoid damaging the SST connector and wire harness.

SB SST

Locking Button

B114456E01

Battery 10 m (33 ft)

SST B114480E01

(2) Move the SST at least 10 m (33 ft) away from the front of the vehicle. SST 09082-00700 (3) Close the doors and windows of the vehicle. HINT: Do not close the windows fully. Leave a gap for inserting the SST wire harness. NOTICE: Do not damage the SST wire harness. (4) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. (e) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) of the vehicle. (2) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the SST activation switch LED light. (f) Disconnect SST. (g) Dispose of the front seat outer belt (with the seat belt pretensioner). HINT: When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with the activated front seat outer belt still installed.


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–87

CAUTION: • Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. • Use gloves and safety glasses when handling an front seat outer belt with a pretensioner that has been activated. • Always wash your hands with water after completing the operation. • Do not apply water to a front seat outer belt that has an activated pretensioner. 2.

10 cm (0.328 ft)

DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (When not Installed in Vehicle) HINT: Prepare a battery as the power source to activate the seat belt pretensioner. NOTICE: • When only disposing of the front seat outer belt (with the seat belt pretensioner), never use the customer's vehicle to activate the seat belt pretensioner. • Follow the procedure described below when activating the seat belt pretensioner. (a) Remove the front seat outer belt assembly (See page SB-75). (b) Wind the seat belt with the retractor. (c) When the seat belt is sufficiently wound, cut the seat belt approximately 10 cm (0.328 ft) from the retractor, as shown in the illustration. HINT: The retractor resistance increases in correlation with how much the seat belt is wound.

Cut

B114471E01

(d) Check whether SST is functioning. SST 09082-00700 CAUTION: Always use the specified SST when activating the seat belt pretensioner.

SST

B104819E01

SB


SBâ&#x20AC;&#x201C;88

SEAT BELT â&#x20AC;&#x201C; FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

Battery

SB

(1) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. HINT: Do not connect the yellow connector. The yellow connector is for connections to the seat belt pretensioner.

SST B104820E01

(2) Press the SST activation switch and check that the LED of the SST activation switch turns on. CAUTION: If the LED turns on when the activation switch is not being pressed, SST may be malfunctioning. Do not use SST.

SST B104821E01

(e) Connect SST. (1) Connect SST, then connect the yellow connector to the seat belt pretensioner. SST 09082-00770 NOTICE: Do not lock the secondary lock of the twin lock to avoid damaging the SST connector and wire harness. SST

Locking Button B114472E01

(2) Using a service-purpose wire harness for the vehicle, tie the seat belt pretensioner to the tire with a wheel attached. Stripped wire harness section: A

Stripped Wire Harness Section B104882E01

Area A

Measurement 2

1.25 mm or more (0.0019 in2 or more)


SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–89

CAUTION: • Do not use wire harnesses that are too thin or any other object to tie the seat belt pretensioner because they may snap due to the shock when the pretensioner is deployed. • Always use a wire harness for vehicle use, with a cross section of at least 1.25 mm2 (0.0019 in2). HINT: To calculate the area of the stripped wire harness cross section: Area = 3.14 x (Diameter)2 divided by 4 (3) Connect SST. SST 09082-00700 NOTICE: • Do not lock the secondary lock of the twin lock to avoid damaging the SST connector and wire harness. • Set up the front seat outer belt as shown in the illustration.

SST Wire Harness

B114473E01

(4) Move SST at least 10 m (33 ft) away from the wheel. NOTICE: Do not damage the SST wire harness. (f) Activate the seat belt pretensioner. (1) Connect the SST red clip to the positive battery terminal and the black clip to the negative battery terminal. (2) Check that no one is within 10 m (33 ft) of the wheel. (3) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the SST activation switch LED light. (g) Disconnect SST.

Battery

10 m (33 ft) SST B114550E01

SB


SB–90

SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

Plastic Bag

SB B114475E01

(h) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: • Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. • Use gloves and safety glasses when handling a front seat outer belt with a pretensioner that has been activated. • Always wash your hands with water after completing the operation. • Do not apply water to a front seat outer belt that has an activated pretensioner. (1) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts.


SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Sedan)

SB–89

REAR SEAT INNER BELT ASSEMBLY (for Sedan) SEAT BELT RESTRAINTS

COMPONENTS

SB

for 60/40 Split Seat Type: REAR SEAT INNER BELT ASSEMBLY

REAR SEAT INNER BELT ASSEMBLY

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY 42 (430, 31)

42 (430, 31)

N*m (kgf*cm, ft*lbf) : Specified torque B138566E01


SB–90

SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Sedan)

REMOVAL 1.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (a) for 60/40 Split Seat Type: (1) Remove the rear seat cushion cover pad (See page SE-46). (b) for Fixed Seat Type: (1) Remove the rear seat cushion cover pad (See page SE-106).

2.

REMOVE REAR SEAT INNER BELT ASSEMBLY (a) for RH Side (for 60/40 Split Seat Type): (1) Remove the bolt and the rear seat inner belt.

SB

B134907

(b) LH Side: (1) Remove the bolt and the rear seat inner belt.

B134904

INSTALLATION 1.

Locating Mark

Arrow Mark B134908E01

INSTALL REAR SEAT INNER BELT ASSEMBLY (a) for RH Side (60/40 Split Seat Type): (1) Install the rear seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: • Install the anchor plate with the arrow mark facing forward. • Do not place the anchor plate over the locating mark area of the floor panel.


SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Sedan)

SB–91

(b) for LH Side: (1) Install the rear seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: • Install the anchor plate with the arrow mark facing forward. • Do not place the anchor plate over the locating mark area of the floor panel. 2.

Locating Mark

Arrow Mark B134905E01

INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (a) for 60/40 Split Seat Type: (1) Install the rear seat cushion cover pad (See page SE-53). (b) for Fixed Seat Type: (1) Install the rear seat cushion cover pad (See page SE-109).

SB


SB–92

SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Hatchback LH Side)

REAR SEAT INNER BELT ASSEMBLY (for Hatchback LH Side) SEAT BELT RESTRAINTS

COMPONENTS

SB

for 60/40 Split Seat Type: NO. 1 REAR SEAT LEG COVER

REAR SEAT INNER BELT ASSEMBLY

42 (430, 31)

NO. 2 REAR SEAT LEG COVER

37 (375, 27)

x3

REAR SEAT CUSHION ASSEMBLY

for Hold Down Seat Type:

REAR SEAT INNER BELT ASSEMBLY

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

42 (430, 31)

N*m (kgf*cm, ft*lbf) : Specified torque B117789E02


SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Hatchback LH Side)

SB–93

REMOVAL NOTICE: Always use "Torx" socket wrench E10 when removing the rear seat. 1.

REMOVE NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-71)

2.

REMOVE NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-70)

3.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE114)

4.

REMOVE REAR SEAT INNER BELT ASSEMBLY (a) for 60/40 Split Seat Type: (1) Using "Torx" socket wrench E10, remove the 3 bolts and pull up the rear seat cushion.

B114740

(2) Remove the belt from the band. (3) Remove the bolt and the rear seat inner belt.

Band B114647E01

(b) for Hold Down Seat Type: (1) Remove the bolt and the rear seat inner belt.

B119857

SB


SB–94

SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Hatchback LH Side)

INSTALLATION NOTICE: Always use "Torx" socket wrench E10 when installing the rear seat. 1.

SB Convex

INSTALL REAR SEAT INNER BELT ASSEMBLY (a) for 60/40 Split Seat Type: (1) Install the rear seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: Do not place the anchor plate over the convex area of the rear seat back frame. (2) Install the belt into the band.

Band B114648E01

(3) Install the rear seat cushion. (4) Using "Torx" socket wrench E10, tighten the 3 bolts in the sequence shown in the illustration. Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf)

3 2

1 B114740E01

(b) for Hold Down Seat Type: (1) Install the rear seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: • Install the anchor plate with the arrow mark facing forward. • Do not place the anchor plate over the locating mark area of the floor panel.

Arrow Mark

Locating Mark B119858E02

2.

INSTALL NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-85)

3.

INSTALL NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-85)

4.

INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE123)


SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Hatchback RH Side)

SB–95

REAR SEAT INNER BELT ASSEMBLY (for Hatchback RH Side) SEAT BELT RESTRAINTS

COMPONENTS for 60/40 Split Seat Type:

SB

PACKAGE TRAY TRIM PANEL ASSEMBLY

DECK BOARD SUB-ASSEMBLY

DECK FLOOR BOX

REAR SEAT ASSEMBLY

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

x6

42 (430, 31)

REAR SEAT INNER BELT ASSEMBLY

N*m (kgf*cm, ft*lbf) : Specified torque B114642E02


SB–96

SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Hatchback RH Side)

for Hold Down Seat Type:

SB

REAR SEAT INNER BELT ASSEMBLY

42 (430, 31)

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

N*m (kgf*cm, ft*lbf) : Specified torque B119856E03


SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Hatchback RH Side)

SB–97

REMOVAL NOTICE: Always use "Torx" socket wrench E10 when removing the rear seat. 1.

REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for 60/40 Split Seat Type) (See page IR-48)

2.

REMOVE DECK BOARD SUB-ASSEMBLY (for 60/40 Split Seat Type) (See page IR-48)

3.

REMOVE DECK FLOOR BOX (for 60/40 Split Seat Type) (See page IR-48)

4.

REMOVE NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-89)

5.

REMOVE REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (See page SE-89)

6.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE114)

7.

REMOVE REAR SEAT INNER BELT ASSEMBLY (a) for 60/40 Split Seat Type: (1) Remove the belt from the band. (2) Remove the bolt and the rear seat inner belt.

Band

B114643E01

(b) for Hold Down Seat Type: (1) Remove the bolt and the rear seat inner belt.

B119859

SB


SB–98

SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Hatchback RH Side)

INSTALLATION NOTICE: Always use "Torx" socket wrench E10 when installing the rear seat. 1.

SB

Band

Convex

INSTALL REAR SEAT INNER BELT ASSEMBLY (a) for 60/40 Split Seat Type: (1) Install the rear seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: Do not place the anchor plate over the convex areas of the rear seat back frame. (2) Install the belt into the band.

B114644E01

(b) for Hold Down Seat Type: (1) Install the rear seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: • Install the anchor plate with the arrow mark facing forward. • Do not place the anchor plate over the locating mark area of the floor panel.

Arrow Mark Locating Mark

2.

INSTALL REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (See page SE-102)

3.

INSTALL NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-103)

4.

INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE123)

5.

INSTALL DECK FLOOR BOX (for 60/40 Split Seat Type) (See page IR-83)

6.

INSTALL DECK BOARD SUB-ASSEMBLY (for 60/40 Split Seat Type) (See page IR-83)

7.

INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for 60/40 Split Seat Type) (See page IR-83)

B119860E02


SB–99

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

REAR SEAT OUTER BELT ASSEMBLY (for Sedan) SEAT BELT RESTRAINTS

COMPONENTS for 60/40 Split Seat Type:

SB

REAR SEAT OUTER BELT ASSEMBLY

REAR CENTER SEAT OUTER BELT ASSEMBLY

REAR SEAT OUTER BELT ASSEMBLY

REAR SEATBACK ASSEMBLY RH

x2 REAR SEATBACK ASSEMBLY LH x2

37 (375, 27)

37 (375, 27)

REAR SEAT INNER BELT ASSEMBLY RH

37 (375, 27)

37 (375, 27)

REAR SEAT INNER BELT ASSEMBLY LH

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY N*m (kgf*cm, ft*lbf) : Specified torque B138665E04


SB–100

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

for Fixed Seat Type:

SB

REAR SEAT OUTER BELT ASSEMBLY RH

REAR CENTER SEAT OUTER BELT ASSEMBLY

REAR SEAT OUTER BELT ASSEMBLY LH

7.9 (80, 70 in.*lbf)

x3 REAR SEATBACK ASSEMBLY

REAR SEAT INNER BELT ASSEMBLY RH

REAR SEAT INNER BELT ASSEMBLY LH

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

N*m (kgf*cm, ft*lbf) : Specified torque B138611E01


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–101

for 60/40 Split Seat Type:

SB LUGGAGE COMPARTMENT FLOOR MAT

SPARE WHEEL COVER ASSEMBLY

LUGGAGE COMPARTMENT TRIM INNER PAD

for Grand Tire:

LUGGAGE COMPARTMENT TRIM INNER PAD

B138565E01


SB–102

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

w/ Curtain Shield Airbag:

SB REAR DOOR OPENING TRIM WEATHERSTRIP RH

ROOF SIDE INNER GARNISH RH

w/ Curtain Shield Airbag:

REAR SEAT SIDE COVER RH

REAR DOOR SCUFF PLATE RH

REAR DOOR OPENING TRIM WEATHERSTRIP LH

ROOF SIDE INNER GARNISH LH

REAR SEAT SIDE COVER LH

REAR DOOR SCUFF PLATE LH Non-reusable part B138449E01


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–103

w/o Rear Spoiler:

HIGH MOUNTED STOP LIGHT ASSEMBLY

HIGH MOUNTED STOP LIGHT CONNECTOR

x4

PACKAGE TRAY TRIM PANEL ASSEMBLY

42 (430, 31)

REAR SEAT OUTER BELT ASSEMBLY

42 (430, 31)

SEAT BELT HOLE SEAL

N*m (kgf*cm, ft*lbf) : Specified torque B138567E01

SB


SB–104

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

REMOVAL HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified.

SB

1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (w/o Rear Spoiler)

2.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (a) for 60/40 Split Seat Type: (1) Remove the rear seat cushion cover pad (See page SE-46). (b) for Fixed Seat Type: (1) Remove the rear seat cushion cover pad (See page SE-106).

3.

REMOVE REAR SEATBACK ASSEMBLY RH (for 60/ 40 Split Seat Type) (See page SE-57)

4.

REMOVE REAR SEATBACK ASSEMBLY LH (for 60/ 40 Split Seat Type) (See page SE-46)

5.

REMOVE REAR SEATBACK ASSEMBLY (for Fixed Seat Type) (See page SE-106)

6.

REMOVE LUGGAGE COMPARTMENT FLOOR MAT (for 60/40 Split Seat Type) (See page ED-133)

7.

REMOVE SPARE WHEEL COVER ASSEMBLY (for 60/ 40 Split Seat Type) (See page ED-133)

8.

REMOVE LUGGAGE COMPARTMENT TRIM INNER PAD (for 60/40 Split Seat Type) (See page ED-134)

9.

REMOVE REAR DOOR SCUFF PLATE RH (See page IR-15)

10. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-15) 11. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page AV-173) 12. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page AV-173) 13. REMOVE REAR SEAT SIDE COVER RH (See page IR16) 14. REMOVE REAR SEAT SIDE COVER LH (See page IR16) 15. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-16) 16. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-16) 17. REMOVE HIGH MOUNTED STOP LIGHT ASSEMBLY (w/o Rear Spoiler) (See page LI-141)


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–105

18. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page AV-173) 19. REMOVE REAR SEAT OUTER BELT ASSEMBLY (a) Remove the bolt. (b) Disengage the 2 claws and remove the anchor plate.

SB B134917

(c) Remove the bolt, the hook and the retractor.

B134918

20. REMOVE SEAT BELT HOLE SEAL (a) Disengage the 2 claws and remove the seat belt hole seal.

B134919


SB–106

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

INSTALLATION HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

INSTALL SEAT BELT HOLE SEAL (a) Engage the 2 claws and install the seat belt hole seal.

2.

INSTALL REAR SEAT OUTER BELT ASSEMBLY (a) Check the angle of inclination required to lock the retractor. (1) Gently incline the retractor from its initial position. Check that the belt does not lock when the retractor is inclined 15° or less in any direction. Also, check that the belt locks when the inclination of the retractor is 45° or more. NOTICE: Do not disassemble the retractor. If the operation is not as specified, replace the rear seat outer belt.

SB

B134919

Unlock

45°

Lock

B134915E01

(b) Insert the hook into the body hole and install the retractor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

B134918

B134917

(c) Engage the 2 claws and install the anchor plate. (d) Tighten the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (e) Check that the ELR locks. NOTICE: • The check should be performed with the rear seat outer belt installed. • Do not allow the anchor part of the rear seat outer belt and the protruding parts of the floor panel to overlap.


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–107

(1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the rear seat outer belt. 3.

INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page AV-174)

4.

INSTALL HIGH MOUNTED STOP LIGHT ASSEMBLY (w/o Rear Spoiler) (See page LI-142)

5.

INSTALL ROOF SIDE INNER GARNISH RH (See page IR-32)

6.

INSTALL ROOF SIDE INNER GARNISH LH (See page IR-33)

7.

INSTALL REAR SEAT SIDE COVER RH (See page IR33)

8.

INSTALL REAR SEAT SIDE COVER LH (See page IR33)

9.

INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page AV-175)

10. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page AV-175) 11. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-34) 12. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-34) 13. INSTALL LUGGAGE COMPARTMENT TRIM INNER PAD (for 60/40 Split Seat Type) (See page ED-136) 14. INSTALL SPARE WHEEL COVER ASSEMBLY (for 60/ 40 Split Seat Type) (See page ED-137) 15. INSTALL LUGGAGE COMPARTMENT FLOOR MAT (for 60/40 Split Seat Type) (See page ED-137) 16. INSTALL REAR SEATBACK ASSEMBLY RH (for 60/ 40 Split Seat Type) (See page SE-65) 17. INSTALL REAR SEATBACK ASSEMBLY LH (for 60/40 Split Seat Type) (See page SE-52) 18. INSTALL REAR SEATBACK ASSEMBLY (for Fixed Seat Type) (See page SE-108) 19. INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (a) for 60/40 Split Seat Type: (1) Install the rear seat cushion cover pad (See page SE-53). (b) for Fixed Seat Type: (1) Install the rear seat cushion cover pad (See page SE-109).

SB


SB–108

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/o Rear Spoiler) Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

SB


SB–106

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

INSTALLATION HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

INSTALL SEAT BELT HOLE SEAL (a) Engage the 2 claws and install the seat belt hole seal.

2.

INSTALL REAR SEAT OUTER BELT ASSEMBLY (a) Check the angle of inclination required to lock the retractor. (1) Gently incline the retractor from its initial position. Check that the belt does not lock when the retractor is inclined 15° or less in any direction. Also, check that the belt locks when the inclination of the retractor is 45° or more. NOTICE: Do not disassemble the retractor. If the operation is not as specified, replace the rear seat outer belt.

SB

B134919

Unlock

45°

Lock

B134915E01

(b) Insert the hook into the body hole and install the retractor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

B134918

B134917

(c) Engage the 2 claws and install the anchor plate. (d) Tighten the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (e) Check that the ELR locks. NOTICE: • The check should be performed with the rear seat outer belt installed. • Do not allow the anchor part of the rear seat outer belt and the protruding parts of the floor panel to overlap.


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–107

(1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the rear seat outer belt. 3.

INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page AV-174)

4.

INSTALL HIGH MOUNTED STOP LIGHT ASSEMBLY (w/o Rear Spoiler) (See page LI-142)

5.

INSTALL ROOF SIDE INNER GARNISH RH (See page IR-32)

6.

INSTALL ROOF SIDE INNER GARNISH LH (See page IR-33)

7.

INSTALL REAR SEAT SIDE COVER RH (See page IR33)

8.

INSTALL REAR SEAT SIDE COVER LH (See page IR33)

9.

INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page AV-175)

10. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page AV-175) 11. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-34) 12. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-34) 13. INSTALL LUGGAGE COMPARTMENT TRIM INNER PAD (for 60/40 Split Seat Type) (See page ED-136) 14. INSTALL SPARE WHEEL COVER ASSEMBLY (for 60/ 40 Split Seat Type) (See page ED-137) 15. INSTALL LUGGAGE COMPARTMENT FLOOR MAT (for 60/40 Split Seat Type) (See page ED-137) 16. INSTALL REAR SEATBACK ASSEMBLY RH (for 60/ 40 Split Seat Type) (See page SE-65) 17. INSTALL REAR SEATBACK ASSEMBLY LH (for 60/40 Split Seat Type) (See page SE-52) 18. INSTALL REAR SEATBACK ASSEMBLY (for Fixed Seat Type) (See page SE-108) 19. INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (a) for 60/40 Split Seat Type: (1) Install the rear seat cushion cover pad (See page SE-53). (b) for Fixed Seat Type: (1) Install the rear seat cushion cover pad (See page SE-109).

SB


SB–108

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Sedan)

20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/o Rear Spoiler) Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

SB


SB–108

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door) SEAT BELT RESTRAINTS

COMPONENTS

SB

PACKAGE TRAY TRIM PANEL ASSEMBLY

DECK BOARD SUB-ASSEMBLY

DECK FLOOR BOX

DECK FLOOR BOX

B127707E02


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–109

for 60/40 Split Seat Type:

REAR SEAT ASSEMBLY

NO. 1 REAR SEAT LEG COVER

SB

37 (375, 27)

REAR SEAT ASSEMBLY

x6

NO. 2 REAR SEAT LEG COVER

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

x7

for Hold Down Seat Type:

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

REAR SEATBACK ASSEMBLY

37 (375, 27)

x4

N*m (kgf*cm, ft*lbf) : Specified torque B121713E05


SB–110

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB w/ Curtain Shield Airbag:

42 (430, 31)

ROOF SIDE INNER GARNISH REAR CENTER SEAT OUTER BELT ASSEMBLY DECK TRIM SIDE PANEL ASSEMBLY

REAR SEAT OUTER BELT ASSEMBLY

42 (430, 31)

x2

REAR DOOR OPENING TRIM WEATHERSTRIP

REAR SEAT SHOULDER BELT HANGER

42 (430, 31)

REAR DOOR SCUFF PLATE

SEAT BELT HOLE SEAL

x2 REAR DECK TRIM COVER

N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part B114430E02


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–111

REMOVAL CAUTION: Always use "Torx" socket wrench E10 when removing the rear seat. HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for LH Side)

2.

REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-48)

3.

REMOVE DECK BOARD SUB-ASSEMBLY (See page IR-48)

4.

REMOVE DECK FLOOR BOX (a) for RH Side: (1) Remove the deck floor box (See page IR-48). (b) for LH Side: HINT: Use the same procedure as for the RH side.

5.

REMOVE NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH Side: (1) Remove the No. 1 rear seat leg cover (See page SE-89). (b) for LH Side: (1) Remove the No. 1 rear seat leg cover (See page SE-70).

6.

REMOVE NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type LH Side) (See page SE-70)

7.

REMOVE REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (a) for RH Side: (1) Remove the rear seat assembly (See page SE89). (b) for LH Side: (1) Remove the rear seat assembly (See page SE71).

8.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE114)

9.

REMOVE REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-115)

10. REMOVE REAR DOOR SCUFF PLATE (See page IR51)

SB


SB–112

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

11. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP (a) Remove the rear door opening trim weatherstrip to the extent that the deck trim side panel and roof side inner garnish can be removed. 12. REMOVE REAR DECK TRIM COVER (See page IR-49)

SB B114431

13. REMOVE DECK TRIM SIDE PANEL ASSEMBLY (a) Remove the belt of the rear seat outer belt from the rear seat shoulder belt hanger.

B114289

(b) Remove the bolt. (c) Disengage the clip and remove the anchor plate of the rear seat outer belt.

B130498

(d) for RH side: (1) Remove the 3 screws. (2) Disengage the 3 clips and the 6 claws and remove the deck trim side panel.

B114573


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–113

(e) for LH side: (1) Remove the 3 screws. (2) Disengage the 3 clips and the 6 claws. (3) Disconnect the luggage compartment room light connector and remove the deck trim side panel.

SB

B114574

14. REMOVE REAR SEAT SHOULDER BELT HANGER (a) Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the rear seat shoulder belt hanger.

Protective Tape B114433E01

15. REMOVE REAR CENTER SEAT OUTER BELT ASSEMBLY (for RH Side) (a) Using a screwdriver with its tip wrapped in protective tape, disengage the 4 claws and remove the center belt guide.

Protective Tape B114462E01


SBâ&#x20AC;&#x201C;114

SB

SEAT BELT â&#x20AC;&#x201C; REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

16. REMOVE ROOF SIDE INNER GARNISH (a) for RH Side (w/ Curtain Shield Airbag): NOTICE: Replace the special clip with a new one because it is damaged when the roof side inner garnish is removed. (1) Disengage the 5 clips. (2) Pass the rear seat outer and rear center seat outer belts through the slit in the roof side inner garnish and remove the roof side inner garnish.

Special Clip

B114576E01

(b) for RH Side (w/o Curtain Shield Airbag): (1) Disengage the 5 clips. (2) Pass the rear seat outer and rear center seat outer belts through the slit in the roof side inner garnish and remove the roof side inner garnish.

B114575

Special Clip

(c) for LH Side (w/ Curtain Shield Airbag): NOTICE: Replace the special clip with a new one because it is damaged when the roof side inner garnish is removed. (1) Disengage the 5 clips. (2) Pass the rear seat outer belt through the slit in the roof side inner garnish and remove the roof side inner garnish.

B114578E01

(d) for LH Side (w/o Curtain Shield Airbag): (1) Disengage the 5 clips. (2) Pass the rear seat outer belt through the slit in the roof side inner garnish and remove the roof side inner garnish.

B114577


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–115

17. REMOVE REAR SEAT OUTER BELT ASSEMBLY (a) Remove the bolt and the through anchor.

SB B114434

(b) Remove the bolt, the 2 hooks and the retractor.

B114435

18. REMOVE SEAT BELT HOLE SEAL (a) Disengage the 2 claws and remove the seat belt hole seal.

B114436


SB–116

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

INSTALLATION CAUTION: Always use "Torx" socket wrench E10 when installing the rear seat. HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified.

SB

1.

INSTALL SEAT BELT HOLE SEAL (a) Engage the 2 claws and install the seat belt hole seal.

2.

INSTALL REAR SEAT OUTER BELT ASSEMBLY (a) Check the angle of inclination required to lock the retractor. (1) Gently incline the retractor from its initial position. Check that the belt does not lock when the retractor is inclined 15° or less in any direction. Also, check that the belt locks when the inclination of the retractor is 45° or more. NOTICE: Do not disassemble the retractor. If the operation is not as specified, replace the rear seat outer belt.

B114436

Unlock 45° Lock

B114437E01

(b) Hook the lower stay of the retractor onto the 2 body hooks and install the retractor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

B114435

B114434

(c) Install the through anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (d) Check that the ELR locks. NOTICE: Perform the check with the rear seat outer belt installed. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the rear seat outer belt.


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

3.

Special Clip

SB–117

INSTALL ROOF SIDE INNER GARNISH (a) for RH Side (w/ Curtain Shield Airbag): (1) Install a new special clip. (2) Pass the rear seat outer and rear center seat outer belts through the slit in the roof side inner garnish. (3) Engage the 5 clips and install the roof side inner garnish.

B114576E01

(b) for RH Side (w/o Curtain Shield Airbag): (1) Pass the rear seat outer and rear center seat outer belts through the slit in the roof side inner garnish. (2) Engage the 5 clips and install the roof side inner garnish.

B114575

(c) for LH Side (w/ Curtain Shield Airbag): (1) Install a new special clip. (2) Pass the rear seat outer belt through the slit in the roof side inner garnish. (3) Engage the 5 clips and install the roof side inner garnish. Special Clip

B114578E01

(d) for LH Side (w/o Curtain Shield Airbag): (1) Pass the rear seat outer belt through the slit in the roof side inner garnish. (2) Engage the 5 clips and install the roof side inner garnish.

B114577

SB


SB–118

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

4.

INSTALL REAR CENTER SEAT OUTER BELT ASSEMBLY (for RH Side) (a) Engage the 4 claws and install the center belt guide.

5.

INSTALL REAR SEAT SHOULDER BELT HANGER (a) Engage the 2 claws and install the rear seat shoulder belt hanger.

6.

INSTALL DECK TRIM SIDE PANEL ASSEMBLY (a) for RH Side: (1) Engage the 3 clips and the 6 claws and install the deck trim side panel. (2) Tighten the 3 screws.

SB B114468

B119901

B114573


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–119

(b) for LH Side: (1) Connect the luggage compartment room light connector. (2) Engage the 3 clips and the 6 claws and install the deck trim side panel. (3) Tighten the 3 screws.

SB

B114574

(c) Engage the clip and install the anchor plate of the rear seat outer belt. (d) Tighten the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

B130498

(e) Install the belt of the rear seat outer belt into the rear seat shoulder belt hanger. 7.

INSTALL REAR DECK TRIM COVER (See page IR-82)

8.

INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP (a) Install the rear door opening trim weatherstrip.

9.

INSTALL REAR DOOR SCUFF PLATE (See page IR80)

B114289

B114431

10. INSTALL REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (a) for RH Side: (1) Install the rear seat assembly (See page SE102).


SB–120

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

(b) for LH Side: (1) Install the rear seat assembly (See page SE84). 11. INSTALL NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type LH Side) (See page SE-85)

SB

12. INSTALL NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH Side: (1) Install the No. 1 rear seat leg cover (See page SE-103). (b) for LH Side: (1) Install the No. 1 rear seat leg cover (See page SE-85). 13. INSTALL REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-122) 14. INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE123) 15. INSTALL DECK FLOOR BOX (a) for RH Side: (1) Install the deck floor box (See page IR-83). (b) for LH Side: HINT: Use the same procedure as for the RH side. 16. INSTALL DECK BOARD SUB-ASSEMBLY (See page IR-83) 17. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-83) 18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for LH Side) Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–121

REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door) SEAT BELT RESTRAINTS

COMPONENTS

SB

PACKAGE TRAY TRIM PANEL ASSEMBLY

DECK BOARD SUB-ASSEMBLY

DECK FLOOR BOX

DECK FLOOR BOX

B127707E02


SB–122

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

for 60/40 Split Seat Type:

SB

REAR SEAT ASSEMBLY

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

REAR SEAT ASSEMBLY

x6

NO. 2 REAR SEAT LEG COVER

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

x7

for Hold Down Seat Type:

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

REAR SEATBACK ASSEMBLY

37 (375, 27)

x4

N*m (kgf*cm, ft*lbf) : Specified torque B121713E05


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

FRONT DOOR OPENING TRIM WEATHERSTRIP

SB–123

REAR SEAT SHOULDER BELT HANGER

FRONT QUARTER TRIM PANEL ASSEMBLY

FRONT DOOR SCUFF PLATE

w/ Curtain Shield Airbag:

42 (430, 31)

REAR CENTER SEAT OUTER BELT ASSEMBLY ROOF SIDE INNER GARNISH

42 (430, 31)

REAR SEAT OUTER BELT ASSEMBLY

x2

DECK TRIM SIDE PANEL ASSEMBLY

42 (430, 31)

SEAT BELT HOLE SEAL N*m (kgf*cm, ft*lbf) : Specified torque

x2 REAR DECK TRIM COVER

Non-reusable part B114481E02

SB


SB–124

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

REMOVAL

SB

NOTICE: Always use "Torx" socket wrench E10 when removing the rear seat. HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for LH Side)

2.

REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-48)

3.

REMOVE DECK BOARD SUB-ASSEMBLY (See page IR-48)

4.

REMOVE DECK FLOOR BOX (a) for RH Side: (1) Remove the deck floor box (See page IR-48). (b) for LH Side: HINT: Use the same procedure as for the RH side.

5.

REMOVE NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH Side: (1) Remove the No. 1 rear seat leg cover (See page SE-89). (b) for LH Side: (1) Remove the No. 1 rear seat leg cover (See page SE-70).

6.

REMOVE NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type LH Side) (See page SE-70)

7.

REMOVE REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (a) for RH Side: (1) Remove the rear seat assembly (See page SE89). (b) for LH Side: (1) Remove the rear seat assembly (See page SE71).

8.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE114)

9.

REMOVE REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-115)

10. REMOVE FRONT DOOR SCUFF PLATE (See page IR97) 11. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP (See page SB-76)


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–125

12. REMOVE REAR SEAT SHOULDER BELT HANGER (a) Remove the belt of the rear seat outer belt.

SB B114498

(b) Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the rear seat shoulder belt hanger.

Protective Tape B114484E01

13. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY (a) Disengage the 8 clips, the retainer and the 10 claws and remove the front quarter trim panel. 14. REMOVE REAR DECK TRIM COVER (See page IR-49)

B114499

15. REMOVE DECK TRIM SIDE PANEL ASSEMBLY (a) Remove the bolt. (b) Disengage the clip and the anchor plate of the rear seat outer belt.

B114500


SB–126

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

(c) for RH Side: (1) Remove the 3 screws. (2) Disengage the 3 clips and the 3 claws and remove the deck trim side panel.

SB

B114501

(d) for LH Side: (1) Remove the 3 screws. (2) Disengage the 3 clips and the 3 claws. (3) Disconnect the luggage compartment room light connector and remove the deck trim side panel. 16. REMOVE REAR CENTER SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-113)

B114502

Special Clip

B114504E01

17. REMOVE ROOF SIDE INNER GARNISH (a) for RH Side (w/ Curtain Shield Airbag): NOTICE: Replace the special clip with a new one because it is damaged when the roof side inner garnish is removed. (1) Disengage the 4 clips and the claw. (2) Pass the rear seat outer and rear center seat outer belts through the slit in the roof side inner garnish and remove the roof side inner garnish.


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–127

(b) for RH Side (w/o Curtain Shield Airbag): (1) Disengage the 4 clips and the claw. (2) Pass the rear seat outer and rear center seat outer belts through the slit in the roof side inner garnish and remove the roof side inner garnish.

SB B114505

(c) for LH Side (w/ Curtain Shield Airbag): NOTICE: Replace the special clip with a new one because it is damaged when the roof side inner garnish is removed. (1) Disengage the 4 clips and the claw. (2) Pass the rear seat outer belt through the slit in the roof side inner garnish and remove the roof side inner garnish.

Special Clip

B114506E01

(d) for LH Side (w/o Curtain Shield Airbag): (1) Disengage the 4 clips and the claw. (2) Pass the rear seat outer belt through the slit in the roof side inner garnish and remove the roof side inner garnish.

B114507

18. REMOVE REAR SEAT OUTER BELT ASSEMBLY (a) Remove the bolt and the through anchor.

B114482


SB–128

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

(b) Remove the bolt, the 2 hooks and the retractor.

SB B114483

19. REMOVE SEAT BELT HOLE SEAL (a) Disengage the 2 claws and remove the seat belt hole seal.

B114436


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–129

INSTALLATION NOTICE: Always use "Torx" socket wrench E10 when installing the rear seat. HINT: The procedure described below is for the RH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

INSTALL SEAT BELT HOLE SEAL (a) Engage the 2 claws and install the seat belt hole seal.

2.

INSTALL REAR SEAT OUTER BELT ASSEMBLY (a) Check the angle of inclination required to lock the retractor. (1) Gently incline the retractor from its initial position. Check that the belt does not lock when the retractor is inclined 15° or less in any direction. Also, check that the belt locks when the inclination of the retractor is 45° or more. NOTICE: Do not disassemble the retractor. If the operation is not as specified, replace the rear seat outer belt.

B114436

Unlock 45° Lock

B114437E01

(b) Hook the lower stay of the retractor onto the 2 body hooks and install the retractor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

B114483

B114482

(c) Install the through anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (d) Check that the ELR locks. NOTICE: Perform the check with the rear seat outer belt installed. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the rear seat outer belt.

SB


SB–130

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

3.

Special Clip

SB

INSTALL ROOF SIDE INNER GARNISH (a) for RH Side (w/ Curtain Shield Airbag): (1) Install a new special clip. (2) Pass the rear seat outer and rear center seat outer belts through the slit in the roof side inner garnish. (3) Engage the 4 clips and the claw and install the roof side inner garnish.

B114504E01

(b) for RH Side (w/o Curtain Shield Airbag): (1) Pass the rear seat outer and rear center seat outer belts through the slit in the roof side inner garnish. (2) Engage the 4 clips and the claw and install the roof side inner garnish.

B114505

(c) for LH Side (w/ Curtain Shield Airbag): (1) Install a new special clip. (2) Pass the rear seat outer belt through the slit in the roof side inner garnish. (3) Engage the 4 clips and the claw and install the roof side inner garnish.

Special Clip

B114506E01

(d) for LH Side (w/o Curtain Shield Airbag): (1) Pass the rear seat outer belt through the slit in the roof side inner garnish. (2) Engage the 4 clips and the claw and install the roof side inner garnish. 4.

B114507

INSTALL REAR CENTER SEAT OUTER BELT ASSEMBLY (for RH Side) (See page SB-117)


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

5.

SB–131

INSTALL DECK TRIM SIDE PANEL ASSEMBLY (a) for RH Side: (1) Engage the 3 clips and the 3 claws and install the deck trim side panel. (2) Tighten the 3 screws.

SB

B114501

(b) for LH Side: (1) Connect the luggage compartment room light connector. (2) Engage the 3 clips and the 3 claws and install the deck trim side panel. (3) Tighten the 3 screws.

B114502

(c) Engage the clip and install the anchor plate of the rear seat outer belt. (d) Tighten the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 6.

B114500

INSTALL REAR DECK TRIM COVER (See page IR-82)


SB–132

SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

7.

INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY (a) Engage the 8 clips, the retainer and the 10 claws and install the front quarter trim panel.

8.

INSTALL REAR SEAT SHOULDER BELT HANGER (a) Engage the 2 claws and install the rear seat shoulder belt hanger.

SB

B114499

B117737

(b) Install the belt of the rear seat outer belt. 9.

INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP (See page SB-80)

10. INSTALL FRONT DOOR SCUFF PLATE (See page IR119)

B114498

11. INSTALL REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (a) for RH Side: (1) Install the rear seat assembly (See page SE102). (b) for LH Side: (1) Install the rear seat assembly (See page SE84). 12. INSTALL NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type LH Side) (See page SE-85) 13. INSTALL NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH Side: (1) Install the No. 1 rear seat leg cover (See pageSE-103 ). (b) for LH Side: (1) Install the No. 1 rear seat leg cover (See page SE-85).


SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–133

14. INSTALL REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-122) 15. INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE123) 16. INSTALL DECK FLOOR BOX (a) for RH Side: (1) Install the deck floor box (See page IR-83). (b) for LH Side: HINT: Use the same procedure as for the RH side. 17. INSTALL DECK BOARD SUB-ASSEMBLY (See page IR-83) 18. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-83) 19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for LH Side) Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

SB


SB–134

SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Sedan)

REAR CENTER SEAT INNER BELT ASSEMBLY (for Sedan) SEAT BELT RESTRAINTS

COMPONENTS

SB

for 60/40 Split Seat Type: REAR CENTER SEAT INNER BELT ASSEMBLY

REAR CENTER SEAT INNER BELT ASSEMBLY

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY 42 (430, 31)

42 (430, 31)

N*m (kgf*cm, ft*lbf) : Specified torque B138566E03


SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Sedan)

SB–135

REMOVAL 1.

2.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (a) for 60/40 Split Seat Type: (1) Remove the rear seat cushion cover pad (See page SE-46). (b) for Fixed Seat Type: (1) Remove the rear seat cushion cover pad (See page SE-106). REMOVE REAR CENTER SEAT INNER BELT ASSEMBLY (a) for RH Side (for 60/40 Split Seat Type): (1) Remove the bolt and the rear center seat inner belt.

B134907

(b) for LH Side: (1) Remove the bolt and the rear center seat inner belt.

B134904

INSTALLATION 1.

Locating Mark

Arrow Mark B134908E01

INSTALL REAR CENTER SEAT INNER BELT ASSEMBLY (a) for RH Side (for 60/40 Split Seat Type): (1) Install the rear center seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: • Install the anchor plate with the arrow mark facing forward. • Do not place the anchor plate over the locating mark area of the floor panel.

SB


SB–136

SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Sedan)

(b) for LH Side: (1) Install the rear center seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: • Install the anchor plate with the arrow mark facing forward. • Do not place the anchor plate over the locating mark area of the floor panel.

SB 2.

Locating Mark

Arrow Mark B134905E01

INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (a) for 60/40 Split Seat Type: (1) Install the rear seat cushion cover pad (See page SE-53). (b) for Fixed Seat Type: (1) Install the rear seat cushion cover pad (See page SE-109).


SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Hatchback LH Side)

SB–137

REAR CENTER SEAT INNER BELT ASSEMBLY (for Hatchback LH Side) SEAT BELT RESTRAINTS

COMPONENTS for 60/40 Split Seat Type:

SB

NO. 1 REAR SEAT LEG COVER

42 (430, 31)

REAR CENTER SEAT INNER BELT ASSEMBLY

NO. 2 REAR SEAT LEG COVER

37 (375, 27)

x3

REAR SEAT CUSHION ASSEMBLY

for Hold Down Seat Type: REAR CENTER SEAT INNER BELT ASSEMBLY

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

37 (375, 27)

N*m (kgf*cm, ft*lbf) : Specified torque B114645E03


SB–138

SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Hatchback LH Side)

REMOVAL NOTICE: Always use "Torx" socket wrench E10 when removing the rear seat.

SB

1.

REMOVE NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-70)

2.

REMOVE NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-70)

3.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE114)

4.

REMOVE REAR CENTER SEAT INNER BELT ASSEMBLY (a) for 60/40 Split Seat Type: (1) Using "Torx" socket wrench E10, remove the 3 bolts and pull up the rear seat cushion.

B114740

(2) Remove the belt from the band. (3) Remove the bolt and the rear center seat inner belt.

Band B114651E01

(b) for Hold Down Seat Type: (1) Remove the bolt and the rear center seat inner belt.

B119857


SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Hatchback LH Side)

SB–139

INSTALLATION NOTICE: Always use "Torx" socket wrench E10 when installing the rear seat. 1.

Band

Convex B114652E01

INSTALL REAR CENTER SEAT INNER BELT ASSEMBLY (a) for 60/40 Split Seat Type (1) Install the rear center seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: Do not place the anchor plate over the convex areas of the rear seat back frame. (2) Install the belt into the band. (3) Install the rear seat cushion. (4) Using "Torx" socket wrench E10, tighten the 3 bolts in the sequence shown in the illustration. Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf)

3 2

1 B114740E01

(b) for Hold Down Seat Type: (1) Install the rear center seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: • Install the anchor plate with the arrow mark facing forward. • Do not place the anchor plate over the locating mark area of the floor panel.

Arrow Mark

2.

INSTALL NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-85)

3.

INSTALL NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-85)

4.

INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE123)

Locating Mark B119858E02

SB


SB–140

SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Hatchback RH Side)

REAR CENTER SEAT INNER BELT ASSEMBLY (for Hatchback RH Side) SEAT BELT RESTRAINTS

COMPONENTS

SB

for 60/40 Split Seat Type:

PACKAGE TRAY TRIM PANEL ASSEMBLY

DECK BOARD SUB-ASSEMBLY

DECK FLOOR BOX

42 (430, 31)

REAR CENTER SEAT INNER BELT ASSEMBLY

NO. 2 REAR SEAT LEG COVER

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

x7

REAR SEAT ASSEMBLY

N*m (kgf*cm, ft*lbf) : Specified torque B114653E02


SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Hatchback RH Side)

SB–141

for Hold Down Seat Type:

SB

REAR CENTER SEAT INNER BELT ASSEMBLY

42 (430, 31)

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

N*m (kgf*cm, ft*lbf) : Specified torque B119856E05


SB–142

SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Hatchback RH Side)

REMOVAL NOTICE: Always use "Torx" socket wrench E10 when removing the rear seat.

SB

1.

REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for 60/40 Split Seat Type) (See page IR-48)

2.

REMOVE DECK BOARD SUB-ASSEMBLY (for 60/40 Split Seat Type) (See page IR-48)

3.

REMOVE DECK FLOOR BOX (for 60/40 Split Seat Type) HINT: Use the same procedure as for the RH side (See page IR-48).

4.

REMOVE NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-70)

5.

REMOVE NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-70)

6.

REMOVE REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (See page SE-71)

7.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE114)

8.

REMOVE REAR CENTER SEAT INNER BELT ASSEMBLY (a) for 60/40 Split Seat Type: (1) Remove the bolt and the rear center seat inner belt.

B114654

(b) for Hold Down Seat Type: (1) Remove the bolt and the rear center seat inner belt.

B119859


SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Hatchback RH Side)

SB–143

INSTALLATION NOTICE: Always use "Torx" socket wrench E10 when installing the rear seat. 1.

Convex

INSTALL REAR CENTER SEAT INNER BELT ASSEMBLY (a) for 60/40 Split Seat Type: (1) Install the rear center seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: Do not place the anchor plate over the convex area of the rear seat back frame.

B114655E01

(b) for Hold Down Seat Type: (1) Install the rear center seat inner belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: • Install the anchor plate with the arrow mark facing forward. • Do not place the anchor plate over the locating mark area of the floor panel. 2.

INSTALL REAR SEAT ASSEMBLY (for 60/40 Split Seat Type) (See page SE-84)

3.

INSTALL NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-85)

4.

INSTALL NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-85)

5.

INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE123)

6.

INSTALL DECK FLOOR BOX (for 60/40 Split Seat Type) HINT: Use the same procedure as for the RH side (See page IR-83).

7.

INSTALL DECK BOARD SUB-ASSEMBLY (for 60/40 Split Seat Type) (See page IR-83)

8.

INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for 60/40 Split Seat Type) (See page IR-83)

Arrow Mark Locating Mark B119860E02

SB


SB–144

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan)

REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan) SEAT BELT RESTRAINTS

COMPONENTS for 60/40 Split Seat Type:

SB

REAR SEAT OUTER BELT ASSEMBLY

REAR CENTER SEAT OUTER BELT ASSEMBLY

REAR SEAT OUTER BELT ASSEMBLY

REAR SEATBACK ASSEMBLY RH

x2 REAR SEATBACK ASSEMBLY LH x2

37 (375, 27)

37 (375, 27)

REAR SEAT INNER BELT ASSEMBLY RH

37 (375, 27)

37 (375, 27)

REAR SEAT INNER BELT ASSEMBLY LH

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY N*m (kgf*cm, ft*lbf) : Specified torque B138665E04


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–145

for Fixed Seat Type:

REAR SEAT OUTER BELT ASSEMBLY RH

REAR CENTER SEAT OUTER BELT ASSEMBLY

SB

REAR SEAT OUTER BELT ASSEMBLY LH

7.9 (80, 70 in.*lbf)

x3 REAR SEATBACK ASSEMBLY

REAR SEAT INNER BELT ASSEMBLY RH

REAR SEAT INNER BELT ASSEMBLY LH

REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

N*m (kgf*cm, ft*lbf) : Specified torque B138611E01


SB–146

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan)

for 60/40 Split Seat Type:

SB LUGGAGE COMPARTMENT FLOOR MAT

SPARE WHEEL COVER ASSEMBLY

LUGGAGE COMPARTMENT TRIM INNER PAD

for Grand Tire:

LUGGAGE COMPARTMENT TRIM INNER PAD

B138565E01


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–147

w/ Curtain Shield Airbag:

SB REAR DOOR OPENING TRIM WEATHERSTRIP RH

ROOF SIDE INNER GARNISH RH

w/ Curtain Shield Airbag:

REAR SEAT SIDE COVER RH

REAR DOOR SCUFF PLATE RH

REAR DOOR OPENING TRIM WEATHERSTRIP LH

ROOF SIDE INNER GARNISH LH

REAR SEAT SIDE COVER LH

REAR DOOR SCUFF PLATE LH Non-reusable part B138449E01


SB–148

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan)

w/o Rear Spoiler:

SB HIGH MOUNTED STOP LIGHT ASSEMBLY

HIGH MOUNTED STOP LIGHT CONNECTOR

PACKAGE TRAY TRIM PANEL ASSEMBLY

x4

42 (430, 31)

for 60/40 Split Seat Type:

42 (430, 31)

REAR CENTER SEAT OUTER BELT ASSEMBLY

REAR CENTER SEAT OUTER BELT ASSEMBLY

42 (430, 31)

N*m (kgf*cm, ft*lbf) : Specified torque B138564E02


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan)

SB–149

REMOVAL 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (w/o Rear Spoiler)

2.

REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (a) for 60/40 Split Seat Type: (1) Remove the rear seat cushion cover pad (See page SE-46). (b) for Fixed Seat Type: (1) Remove the rear seat cushion cover pad (See page SE-106).

3.

REMOVE REAR SEATBACK ASSEMBLY RH (for 60/ 40 Split Seat Type) (See page SE-57)

4.

REMOVE REAR SEATBACK ASSEMBLY LH (for 60/ 40 Split Seat Type) (See page SE-46)

5.

REMOVE REAR SEATBACK ASSEMBLY (for Fixed Seat Type) (See page SE-106)

6.

REMOVE LUGGAGE COMPARTMENT FLOOR MAT (for 60/40 Split Seat Type) (See page ED-133)

7.

REMOVE SPARE WHEEL COVER ASSEMBLY (for 60/ 40 Split Seat Type) (See page ED-133)

8.

REMOVE LUGGAGE COMPARTMENT TRIM INNER PAD (for 60/40 Split Seat Type) (See page ED-134)

9.

REMOVE REAR DOOR SCUFF PLATE RH (See page IR-15)

10. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-15) 11. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page AV-173) 12. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page AV-173) 13. REMOVE REAR SEAT SIDE COVER RH (See page IR16) 14. REMOVE REAR SEAT SIDE COVER LH (See page IR16) 15. REMOVE ROOF SIDE INNER GARNISH RH (See page IR-16) 16. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-16) 17. REMOVE HIGH MOUNTED STOP LIGHT ASSEMBLY (w/o Rear Spoiler) (See page LI-141) 18. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page AV-173)

SB


SB–150

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan)

19. REMOVE REAR CENTER SEAT OUTER BELT ASSEMBLY (a) for Fixed Seat Type: (1) Remove the bolt and the anchor plate.

SB B138451

(b) Remove the bolt, the hook and the retractor.

B134914

INSTALLATION 1. Unlock

45°

Lock

INSTALL REAR CENTER SEAT OUTER BELT ASSEMBLY (a) Check the angle of inclination required to lock the retractor. (1) Gently incline the retractor from its initial position. Check that the belt does not lock when the retractor is inclined 15° or less in any direction. Also, check that the belt locks when the inclination of the retractor is 45° or more. NOTICE: Do not disassemble the retractor. If the operation is not as specified, replace the rear center seat outer belt.

B134915E01

(b) Insert the hook into the body hole and install the retractor with the bolt.

B134914


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan)

Locating Mark

SB–151

(c) for Fixed Seat Type: (1) Install the anchor plate with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: • Install the anchor plate with the arrow mark facing forward. • Do not place the anchor plate over the locating mark area of the floor panel. (d) Check that the ELR locks. NOTICE: • The check should be performed with the rear seat outer belt installed. • Do not allow the anchor part of the rear seat outer belt and the protruding parts of the floor panel to overlap. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the rear center seat outer belt.

Arrow Mark B138452E01

2.

INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page AV-174)

3.

INSTALL HIGH MOUNTED STOP LIGHT ASSEMBLY (w/o Rear Spoiler) (See page LI-142)

4.

INSTALL ROOF SIDE INNER GARNISH RH (See page IR-32)

5.

INSTALL ROOF SIDE INNER GARNISH LH (See page IR-33)

6.

INSTALL REAR SEAT SIDE COVER RH (See page IR33)

7.

INSTALL REAR SEAT SIDE COVER LH (See page IR33)

8.

INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page AV-175)

9.

INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page AV-175)

10. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-34) 11. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-34) 12. INSTALL LUGGAGE COMPARTMENT TRIM INNER PAD (for 60/40 Split Seat Type) (See page ED-136) 13. INSTALL SPARE WHEEL COVER ASSEMBLY (for 60/ 40 Split Seat Type) (See page ED-137) 14. INSTALL LUGGAGE COMPARTMENT FLOOR MAT (for 60/40 Split Seat Type) (See page ED-137) 15. INSTALL REAR SEATBACK ASSEMBLY RH (for 60/ 40 Split Seat Type) (See page SE-65)

SB


SB–152

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Sedan)

16. INSTALL REAR SEATBACK ASSEMBLY LH (for 60/40 Split Seat Type) (See page SE-52) 17. INSTALL REAR SEATBACK ASSEMBLY (for Fixed Seat Type) (See page SE-108)

SB

18. INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (a) for 60/40 Split Seat Type: (1) Install the rear seat cushion cover pad (See page SE-53). (b) for Fixed Seat Type: (1) Install the rear seat cushion cover pad (See page SE-109). 19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/o Rear Spoiler) Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–153

REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door) SEAT BELT RESTRAINTS

COMPONENTS

SB

PACKAGE TRAY TRIM PANEL ASSEMBLY

DECK BOARD SUB-ASSEMBLY

DECK FLOOR BOX RH

DECK FLOOR BOX LH

B114273E01


SB–154

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

for 60/40 Split Seat Type:

SB

REAR SEAT ASSEMBLY RH

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

REAR SEAT ASSEMBLY LH

x6

NO. 2 REAR SEAT LEG COVER

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

x7

for Hold Down Seat Type:

REAR SEATBACK ASSEMBLY REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

37 (375, 27)

x4

N*m (kgf*cm, ft*lbf) : Specified torque B121713E03


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–155

SB 42 (430, 31)

w/ Curtain Shield Airbag:

ROOF SIDE INNER GARNISH RH

42 (430, 31)

42 (430, 31)

DECK TRIM SIDE PANEL ASSEMBLY RH REAR CENTER SEAT OUTER BELT ASSEMBLY

x2

REAR DOOR OPENING TRIM WEATHERSTRIP RH

42 (430, 31)

x2 REAR DOOR SCUFF PLATE RH

REAR SEAT OUTER BELT ASSEMBLY RH

REAR DECK TRIM COVER

N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part B114457E02


SB–156

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

REAR SEAT SHOULDER BELT COVER

SB SEAT BELT ANCHOR COVER

REAR DOOR OPENING TRIM WEATHERSTRIP LH

ROOF HEADLINING ASSEMBLY

REAR SEAT OUTER BELT ASSEMBLY LH

ROOF SIDE INNER GARNISH LH

w/ Curtain Shield Airbag:

x2

42 (430, 31)

DECK TRIM SIDE PANEL ASSEMBLY LH REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft*lbf) : Specified torque

LUGGAGE COMPARTMENT ROOM LIGHT CONNECTOR

Non-reusable part B114458E03


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–157

REMOVAL CAUTION: Always use "Torx" socket wrench E10 when removing the rear seat. 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2.

REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-48)

3.

REMOVE DECK BOARD SUB-ASSEMBLY (See page IR-48)

4.

REMOVE DECK FLOOR BOX RH (See page IR-48)

5.

REMOVE DECK FLOOR BOX LH (See page IR-48)

6.

REMOVE NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH side: (1) Remove the No. 1 rear seat leg cover (See page SE-89). (b) for LH side: (1) Remove the No. 1 rear seat leg cover (See page SE-70).

7.

REMOVE NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-70)

8.

REMOVE REAR SEAT ASSEMBLY RH (for 60/40 Split Seat Type) (See page SE-89)

9.

REMOVE REAR SEAT ASSEMBLY LH (for 60/40 Split Seat Type) (See page SE-71)

10. REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE114) 11. REMOVE REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-115) 12. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-51) 13. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-51) 14. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page SB-112) 15. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH HINT: Use the same procedure as for the RH side. 16. REMOVE REAR DECK TRIM COVER (See page IR-49) 17. REMOVE REAR SEAT OUTER BELT ASSEMBLY RH (See page IR-51) 18. REMOVE REAR SEAT OUTER BELT ASSEMBLY LH (See page IR-51)

SB


SB–158

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

19. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-52) 20. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-52) 21. REMOVE ROOF SIDE INNER GARNISH RH (a) Using a screwdriver with its tip wrapped in protective tape, disengage the 4 claws and remove the center belt guide.

SB

Protective Tape B114462E01

(b) w/ Curtain Shield Airbag: NOTICE: Replace the special clip with a new one when the roof side inner garnish is removed. (1) Disengage the 5 clips. (2) Pass the rear seat outer belt and the rear center seat outer belt through the slit in the roof side inner garnish and remove the roof side inner garnish.

Special Clip

B114576E01

(c) w/o Curtain Shield Airbag: (1) Disengage the 5 clips. (2) Pass the rear seat outer belt and the rear center seat outer belt through the slit in the roof side inner garnish and remove the roof side inner garnish. 22. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-54) B114575

23. REMOVE REAR CENTER SEAT OUTER BELT ASSEMBLY (a) Remove the 2 tongue plates.

B114459


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–159

(b) Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and open the slip joint cover.

SB

Protective Tape B114460E01

(c) Remove the bolt and the through anchor.

B114461

(d) Remove the bolt, the hook and the bracket.

B114463

(e) Remove the bolt, the 2 hooks and the retractor.

B114551

24. REMOVE SEAT BELT ANCHOR COVER (a) Using a moulding remover, disengage the 4 claws and remove the seat belt anchor cover.

B114464


SB–160

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

25. REMOVE ROOF HEADLINING ASSEMBLY (a) Using a clip remover, remove the clip and the roof headlining.

SB B114465

26. REMOVE REAR SEAT SHOULDER BELT COVER (a) Disengage the 2 claws and remove the rear seat shoulder belt cover.

B114466


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

SB–161

INSTALLATION CAUTION: Always use "Torx" socket wrench E10 when installing the rear seat. 1.

INSTALL REAR SEAT SHOULDER BELT COVER (a) Engage the 2 claws and install the rear seat shoulder belt cover.

B114466

2.

INSTALL ROOF HEADLINING ASSEMBLY (a) Install the roof headlining with the clip.

3.

INSTALL SEAT BELT ANCHOR COVER (a) Engage the 4 claws and install the seat belt anchor cover.

4.

INSTALL REAR CENTER SEAT OUTER BELT ASSEMBLY (a) Check the angle of inclination required to lock the retractor. (1) Gently incline the retractor from its initial position. Check that the belt does not lock when the retractor is inclined 15° or less in any direction. Also, check that the belt locks when the inclination of the retractor is 45° or more. NOTICE: Do not disassemble the retractor. If the operation is not as specified, replace the rear seat outer belt.

B114465

B114467

Unlock 45° Lock

B114437E01

SB


SB–162

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

(b) Hook the lower stay of the retractor onto the 2 body hooks and install the retractor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

SB B114551

B114463

(c) Insert the hook into the body hole and install the bracket with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (d) Check that the ELR locks. NOTICE: Perform the check with the rear center seat outer belt installed. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the rear center seat outer belt. (e) Install the through anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

B114461

(f)

Engage the 2 claws and close the slip joint cover.

B114469

(g) Install the 2 tongue plates.

B114459


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

5.

Special Clip

SB–163

INSTALL ROOF SIDE INNER GARNISH RH (a) w/ Curtain Shield Airbag: (1) Install a new special clip. (2) Pass the rear seat outer belt and the rear center seat outer belt through the slit in the roof side inner garnish. (3) Engage the 5 clips and install the roof side inner garnish.

B114576E01

(b) w/o Curtain Shield Airbag: (1) Pass the rear seat outer belt and the rear center seat outer belt through the slit in the roof side inner garnish. (2) Engage the 5 clips and install the roof side inner garnish.

B114575

(c) Engage the 4 claws and install the center belt guide.

B114468

6.

INSTALL ROOF SIDE INNER GARNISH LH (See page IR-77)

7.

INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-79)

8.

INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-79)

9.

INSTALL REAR SEAT OUTER BELT ASSEMBLY RH (See page IR-79)

10. INSTALL REAR SEAT OUTER BELT ASSEMBLY LH (See page IR-80) 11. INSTALL REAR DECK TRIM COVER (See page IR-82) 12. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page SB-119) 13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH HINT: Use the same procedure as for the RH side. 14. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-80) 15. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-80)

SB


SB–164

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 5 Door)

16. INSTALL REAR SEAT ASSEMBLY LH (for 60/40 Split Seat Type) (See page SE-84) 17. INSTALL REAR SEAT ASSEMBLY RH (for 60/40 Split Seat Type) (See page SE-102) 18. INSTALL NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-85)

SB

19. INSTALL NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH Side: (1) Install the No. 1 rear seat leg cover (See page SE-103). (b) for LH Side: (1) Install the No. 1 rear seat leg cover (See page SE-85). 20. INSTALL REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-122) 21. INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE123) 22. INSTALL DECK FLOOR BOX RH (See page IR-83) 23. INSTALL DECK FLOOR BOX LH (See page IR-83) 24. INSTALL DECK BOARD SUB-ASSEMBLY (See page IR-83) 25. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-83) 26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–165

REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door) SEAT BELT RESTRAINTS

COMPONENTS

SB

PACKAGE TRAY TRIM PANEL ASSEMBLY

DECK BOARD SUB-ASSEMBLY

DECK FLOOR BOX RH

DECK FLOOR BOX LH

B114273E01


SB–166

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

for 60/40 Split Seat Type:

SB

REAR SEAT ASSEMBLY RH

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

REAR SEAT ASSEMBLY LH

x6

NO. 2 REAR SEAT LEG COVER

NO. 1 REAR SEAT LEG COVER

37 (375, 27)

x7

for Hold Down Seat Type:

REAR SEATBACK ASSEMBLY REAR SEAT CUSHION COVER PAD SUB-ASSEMBLY

37 (375, 27)

x4

N*m (kgf*cm, ft*lbf) : Specified torque B121713E03


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–167

SB FRONT DOOR OPENING TRIM WEATHERSTRIP RH

FRONT QUARTER TRIM PANEL ASSEMBLY RH

FRONT DOOR SCUFF PLATE RH

FRONT DOOR OPENING TRIM WEATHERSTRIP LH

FRONT QUARTER TRIM PANEL ASSEMBLY LH

FRONT DOOR SCUFF PLATE LH

B114485E01


SB–168

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB 42 (430, 31)

w/ Curtain Shield Airbag:

ROOF SIDE INNER GARNISH RH

42 (430, 31)

42 (430, 31)

REAR CENTER SEAT OUTER BELT ASSEMBLY

x2

DECK TRIM SIDE PANEL ASSEMBLY RH

REAR SEAT OUTER BELT ASSEMBLY RH

42 (430, 31)

x2 REAR DECK TRIM COVER

N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part B114486E02


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–169

REAR SEAT SHOULDER BELT COVER

SB

SEAT BELT ANCHOR COVER

ROOF HEADLINING ASSEMBLY

ROOF SIDE INNER GARNISH LH

w/ Curtain Shield Airbag: REAR SEAT OUTER BELT ASSEMBLY LH

42 (430, 31)

LUGGAGE COMPARTMENT ROOM LIGHT CONNECTOR

DECK TRIM SIDE PANEL ASSEMBLY LH N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part B114487E02


SB–170

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

REMOVAL NOTICE: Always use "Torx" socket wrench E10 when removing the rear seat.

SB

1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2.

REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-48)

3.

REMOVE DECK BOARD SUB-ASSEMBLY (See page IR-48)

4.

REMOVE DECK FLOOR BOX RH (See page IR-48)

5.

REMOVE DECK FLOOR BOX LH (See page IR-48)

6.

REMOVE NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH Side: (1) Remove the No. 1 rear seat leg cover (See page SE-89). (b) for LH Side: (1) Remove the No. 1 rear seat leg cover (See page SE-70).

7.

REMOVE NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-70)

8.

REMOVE REAR SEAT ASSEMBLY RH (for 60/40 Split Seat Type) (See page SE-89)

9.

REMOVE REAR SEAT ASSEMBLY LH (for 60/40 Split Seat Type) (See page SE-71)

10. REMOVE REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE114) 11. REMOVE REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-115) 12. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-97) 13. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-97) 14. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page SB-76) 15. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH HINT: Use the same procedure as for the RH side. 16. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH (See page IR-97) 17. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH (See page IR-97) 18. REMOVE REAR DECK TRIM COVER (See page IR-49)


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–171

19. REMOVE REAR SEAT OUTER BELT ASSEMBLY RH (See page IR-98) 20. REMOVE REAR SEAT OUTER BELT ASSEMBLY LH (See page IR-98) 21. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-98) 22. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-98) 23. REMOVE ROOF SIDE INNER GARNISH RH (a) Using a screwdriver with its tip wrapped in protective tape, disengage the 4 claws and remove the center belt guide.

Protective Tape B114462E01

Special Clip

(b) w/ Curtain shield Airbag: NOTICE: Replace the special clip with a new one when the roof side inner garnish is removed. (1) Disengage the 4 clips and the claw. (2) Pass the rear seat outer belt and the rear center seat outer belt through the slit in the roof side inner garnish and remove the roof side inner garnish.

B114504E01

(c) w/o Curtain Shield Airbag: (1) Disengage the 4 clips and the claw. (2) Pass the rear seat outer belt and the rear center seat outer belt through the slit in the roof side inner garnish and remove the roof side inner garnish. 24. REMOVE ROOF SIDE INNER GARNISH LH (See page IR-100) B114505

25. REMOVE REAR CENTER SEAT OUTER BELT ASSEMBLY (See page SB-158) 26. REMOVE SEAT BELT ANCHOR COVER (See page SB-159) 27. REMOVE ROOF HEADLINING ASSEMBLY (See page SB-160)

SB


SB–172

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

28. REMOVE REAR SEAT SHOULDER BELT COVER (See page SB-160)

SB


SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

SB–173

INSTALLATION CAUTION: Always use "Torx" socket wrench E10 when installing the rear seat. 1.

INSTALL REAR SEAT SHOULDER BELT COVER (See page SB-160)

2.

INSTALL ROOF HEADLINING ASSEMBLY (See page SB-160)

3.

INSTALL SEAT BELT ANCHOR COVER (See page SB-160)

4.

INSTALL REAR CENTER SEAT OUTER BELT ASSEMBLY (See page SB-161)

5.

INSTALL ROOF SIDE INNER GARNISH RH (a) w/ Curtain Shield Airbag: (1) Install a new special clip onto the roof side inner garnish. (2) Pass the rear seat outer belt and the rear center seat outer belt through the slit in the roof side inner garnish. (3) Engage the 4 clips and the claw and install the roof side inner garnish.

Special Clip

B114504E01

(b) w/o Curtain Shield Airbag: (1) Pass the rear seat outer belt and the rear center seat outer belt through the slit in the roof side inner garnish. (2) Engage the 4 clips and the claw and install the roof side inner garnish.

B114505

(c) Engage the 4 claws and install the center belt guide.

B114468

6.

INSTALL ROOF SIDE INNER GARNISH LH (See page IR-116)

7.

INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-117)

8.

INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-118)

9.

INSTALL REAR SEAT OUTER BELT ASSEMBLY RH (See page IR-118)

SB


SB–174

SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Hatchback 3 Door)

10. INSTALL REAR SEAT OUTER BELT ASSEMBLY LH (See page IR-118) 11. INSTALL REAR DECK TRIM COVER (See page IR-82) 12. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH (See page IR-118)

SB

13. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH (See page IR-119) 14. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page SB-80) 15. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH HINT: Use the same procedure as for the RH side. 16. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-119) 17. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-119) 18. INSTALL REAR SEAT ASSEMBLY LH (for 60/40 Split Seat Type) (See page SE-84) 19. INSTALL REAR SEAT ASSEMBLY RH (for 60/40 Split Seat Type) (See page SE-102) 20. INSTALL NO. 2 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (See page SE-85) 21. INSTALL NO. 1 REAR SEAT LEG COVER (for 60/40 Split Seat Type) (a) for RH Side: (1) Install the No. 1 rear seat leg cover (See page SE-103). (b) for LH Side: (1) Install the No. 1 rear seat leg cover (See page SE-85). 22. INSTALL REAR SEATBACK ASSEMBLY (for Hold Down Seat Type) (See page SE-122) 23. INSTALL REAR SEAT CUSHION COVER PAD SUBASSEMBLY (for Hold Down Seat Type) (See page SE123) 24. INSTALL DECK FLOOR BOX RH (See page IR-83) 25. INSTALL DECK FLOOR BOX LH (See page IR-83) 26. INSTALL DECK BOARD SUB-ASSEMBLY (See page IR-83) 27. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-83) 28. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)


SEAT BELT – CHILD RESTRAINT SEAT ANCHOR BRACKET (for Sedan)

SB–175

CHILD RESTRAINT SEAT ANCHOR BRACKET (for Sedan) SEAT BELT RESTRAINTS

COMPONENTS

SB

x3 x3

42 (430, 31)

CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET

N*m (kgf*cm, ft*lbf) : Specified torque B138377E01


SB–176

SEAT BELT – CHILD RESTRAINT SEAT ANCHOR BRACKET (for Sedan)

REMOVAL 1.

SB

REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET HINT: Use the same procedure to remove all the child restraint seat tether anchor brackets. (a) Disengage the claw and open the package tray trim cover.

B138378

(b) Remove the bolt and the child restraint seat tether anchor bracket.

B138530


SEAT BELT – CHILD RESTRAINT SEAT ANCHOR BRACKET (for Sedan)

SB–177

INSTALLATION 1.

INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET HINT: Use the same procedure to install all the child restraint seat tether anchor brackets. (a) Insert the hook into the body hole and install the child restraint seat tether anchor bracket with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf)

B138379

(b) Engage the claw and close the package tray rim cover.

B138378

SB


SS–1

SERVICE SPECIFICATIONS – STANDARD BOLT

STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt

Stud Bolt

Normal Recess Bolt

Weld Bolt

Class

Deep Recess Bolt No Mark

No Mark

No Mark

4T

5T

w/ Washer

w/ Washer

6T

7T

8T

9T

10T

11T

SS


SS–2

SERVICE SPECIFICATIONS – STANDARD BOLT

SPECIFIED TORQUE FOR STANDARD BOLTS Class

4T

SS 5T

6T

7T

8T

9T

10T

11T

Diameter (mm)

Pitch (mm)

Specified torque

N*m

kgf*cm

ft.*lbf

N*m

kgf*cm

ft.*lbf

6

1

5

55

48 in.*lbf

6

60

52 in.*lbf

8

1.25

12.5

130

9

14

145

10

10

1.25

26

260

19

29

290

21

12

1.25

47

480

35

53

540

39

14

1.5

74

760

55

84

850

61

Hexagon head bolt

Hexagon flange bolt

16

1.5

115

1,150

83

-

-

-

6

1

6.5

65

56 in.*lbf

7.5

75

65 in.*lbf

8

1.25

15.5

160

12

17.5

175

13

10

1.25

32

330

24

36

360

26

12

1.25

59

600

43

65

670

48

14

1.5

91

930

67

100

1,050

76

16

1.5

140

1,400

101

-

-

-

6

1

8

80

69 in.*lbf

9

90

78 in.*lbf

8

1.25

19

195

14

21

210

15

10

1.25

39

400

29

44

440

32

12

1.25

71

730

53

80

810

59

14

1.5

110

1,100

80

125

1,250

90

16

1.5

170

1,750

127

-

-

-

6

1

10.5

110

8

12

120

9

8

1.25

25

260

19

28

290

21

10

1.25

52

530

38

58

590

43

12

1.25

95

970

70

105

1,050

76

14

1.5

145

1,500

108

165

1,700

123

16

1.5

230

2,300

166

-

-

-

8

1.25

29

300

22

33

330

24

10

1.25

61

620

45

68

690

50

12

1.25

110

1,100

80

120

1,250

90

8

1.25

34

340

25

37

380

27

10

1.25

70

710

51

78

790

57

12

1.25

125

1,300

94

140

1,450

105

8

1.25

38

390

28

42

430

31

10

1.25

78

800

58

88

890

64

12

1.25

140

1,450

105

155

1,600

116

8

1.25

42

430

31

47

480

35

10

1.25

87

890

64

97

990

72

12

1.25

155

1,600

116

175

1,800

130


SS–3

SERVICE SPECIFICATIONS – STANDARD BOLT

HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut

Old Standard Hexagon Nut Cold Forging Nut

Class Cutting Processed Nut

No Mark

No Mark (w/ Washer)

4N

No Mark (w/ Washer)

No Mark

5N (4T)

6N

7N (5T)

8N

No Mark

10N (7T)

11N

12N

HINT: • *: Nut with 1 or more marks on one side surface of the nut. • Use the nut with the same number of the nut strength classification or greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: • Bolt = 4T • Nut = 4N or more

SS


SS–4

SERVICE SPECIFICATIONS – 1NZ-FE ENGINE CONTROL SYSTEM

1NZ-FE ENGINE CONTROL SYSTEM SERVICE DATA Standard resistance

6.9 to 7.9 Ω at 20 °C (68°F)

Camshaft position sensor

Standard resistance

1,630 to 2,740 Ω at cold 2,065 to 3,225 Ω at hot

Crankshaft position sensor

Standard resistance

985 to 1,600 Ω at cold 1,265 to 1,890 Ω at hot

Engine coolant temperature sensor

Standard resistance

2.32 to 2.59 kΩ Approximately 20°C (68°F) 0.310 to 0.326 kΩ Approximately 80°C (176°F)

Throttle with motor body assembly

Standard resistance 1 (M-) - 2 (M+)

0.3 to 100 Ω at 20°C (68°F)

EFI (20A) fuse

Standard resistance 1-2

Below 1 Ω

Knock sensor

Standard resistance

120 to 280 kΩ at 20°C (68°F)

Camshaft timing oil control valve assembly

SS

A1 - C1

Below 1 Ω

A1 - A4

10 kΩ or higher

A4-C1

10 kΩ or higher

A1 - A4

Below 1 Ω (Apply battery voltage between terminals A2 and A3)

A4 - C1

Below 1 Ω (Apply battery voltage between terminals A2 and A3)

Accelerator pedal position No. 1 standard voltage

Standard resistance Accelerator pedal released Accelerator pedal depressed

0.5 to 1.1 V 2.6 to 4.5 V

Accelerator pedal position No. 2 standard voltage

Standard resistance Accelerator pedal released Accelerator pedal depressed

1.2 to 2.0 V 3.4 to 5.0 V

Integration relay


SS–5

SERVICE SPECIFICATIONS – 1NZ-FE ENGINE CONTROL SYSTEM

TORQUE SPECIFICATIONS Part tightened

N*m

kgf*cm

ft.*lbf

7.5

76

66 in.*lbf

Fan belt adjusting bar x Oil pump assembly

11

112

8.1

Camshaft position sensor x Cylinder head assembly

8.0

82

71in.*lbf

Crankshaft position sensor x Oil pump assembly

7.5

76

66 in.*lbf

Engine coolant temperature sensor x Cylinder head assembly

20

204

15

Throttle with motor body assembly x Intake manifold

9.0

92

80 in.*lbf

Water filler sub-assembly x Throttle with motor body assembly

7.5

76

66 in.*lbf

Camshaft timing oil control valve assembly x Cylinder head assembly

Throttle with motor body assembly x Wire harness with bracket

9.0

92

80 in.*lbf

Air cleaner cap sub-assembly x Air cleaner hose No. 1

3.0

31

27 in.*lbf

Knock sensor x Cylinder block assembly

20

204

15

Intake manifold x Cylinder block assembly

30

304

22

ECM x body

8.0

82

71

Accelerator pedal assembly x body

5.4

55

48

Battery negative terminal x Battery negative cable

5.4

55

48

SS


SERVICE SPECIFICATIONS – 1NZ-FE ENGINE MECHANICAL

SS–5

1NZ-FE ENGINE MECHANICAL SERVICE DATA New V belt deflection

7.0 to 8.5 mm (0.28 to 0.33 in.)

Used V belt deflection

11.0 to 13.0 mm (0.43 to 0.51 in.)

New V belt tension

539 to 637 N (55 to 65 kgf, 121 to 143 lb)

Used V belt tension

245 to 392 N (25 to 40 kgf, 55 to 88 lb) 8 to 12 °BTDC

Ignition timing Idle speed

Manual transaxle Automatic transaxle

600 +- 50 rpm 700 +- 50 rpm

Compression pressure

1,471 kPa (15.0 kgf/cm 2213 psi)

Minimum pressure

1,079 kPa (11.0 kgf/cm 2156 psi)

Difference between each cylinder

98 kPa (1.0 kgf/cm 214 psi)

Valve clearance (cold)

Intake Exhaust

0.15 to 0.25 mm (0.006 to 0.010 in.) 0.25 to 0.35 mm (0.010 to 0.014 in.)

Chain elongation

Maximum

123.2 mm (4.850 in.)

Camshaft timing gear diameter (w/ chain)

Minimum

96.2 mm (3.787 in.)

Camshaft timing sprocket diameter (w/ chain)

Minimum

96.2 mm (3.787 in.)

Chain tensioner slipper thickness

Maximum

1.0 mm (0.039 in.)

Chain vibration damper thickness

Maximum

1.0 mm (0.039 in.)

Cylinder head set bolt length

Standard Maximum

143.5 mm (5.6496 in.) 144.2 mm (5.6772 in.)

Cylinder head warpage

Maximum cylinder block surface Intake manifold surface Exhaust manifold surface

0.05 mm (0.0020 in.) 0.10 mm (0.0039 in.) 0.10 mm (0.0039 in.)

Intake valve overall length

Standard Minimum

89.25 mm (3.5138 in.) 88.75 mm (3.4941 in.)

Intake valve stem diameter

4.970 to 4.985 mm (0.1957 to 0.1963 in.)

Intake valve margin thickness

Standard Minimum

1.0 mm (0.039 in.) 0.5 mm (0.020 in.)

Exhaust valve overall length

Standard Minimum

87.90 mm (3.4606 in.) 87.40 mm (3.4409 in.)

Exhaust valve stem diameter Exhaust valve margin thickness

4.965 to 4.980 mm (0.1955 to 0.1961 in.) Standard Minimum

Valve spring free length

1.15 mm (0.045 in.) 0.5 mm (0.020 in.) 45.05 to 45.15 mm (1.774 to 1.778 in.)

Valve spring deviation

Maximum

1.6 mm (0.063 in.)

Valve spring angle (reference)

Maximum

Valve spring installed tension at 32.5 mm (1.280 in.) Valve spring working tension at 23.9 mm (0.941 in.)

149 to 165 N (15.2 to 16.8 kgf, 33.5 to 37.1 lbf) Maximum

286 to 316N (29.1 to 32.2 kgf, 64.2 to 71.0 lbf)

Standard intake Standard exhaust

0.025. to 0.060 mm (0.0010 to 0.0024 in.) 0.030. to 0.065 mm (0.0012 to 0.0026 in.)

Maximum intake Maximum exhaust

0.08 mm (0.0032 in.) 0.10 mm (0.039 in.)

Standard O/S

9.685 to 9.706 mm (0.3813 to 0.3821 in.) 9.735 to 9.755 mm (0.3833 to 0.3841 in.)

Bushing inside diameter

Valve guide bushing oil clearance

Valve guide bush diameter

5.010 to 5.030 mm (0.1972 to 0.1980 in.)

Bushing Protrusion height

9.0 to 9.4 mm (0.354 to 0.370 in.)

Lifter diameter

30.966 to 30.976 mm (1.291 to 1.2195 in.)

SS


SS–6

SERVICE SPECIFICATIONS – 1NZ-FE ENGINE MECHANICAL Lifter bore diameter

SS

31.000 to 31.025 mm (1.2205 to 1.2215 in.)

Lifter oil clearance

Standard Maximum

0.024 to 0.059 mm (0.0009 to 0.0023 in.) 0.1 mm (0.0039 in.)

Camshaft circle runout

Maximum

0.03 mm (0.0012 in.)

Camshaft cam lobe height

Standard Minimum

44.617 to 44.717 mm (1.7566 to 1.7605 in.) 43.16 mm (1.6992 in.)

Camshaft No. 1 journal diameter

34.449 to 34.465 mm (1.3563 to 1.3569 in.)

Camshaft other journals diameter

22.949 to 22.965 mm (0.9035 to 0.9041 in.)

No. 2 camshaft circle runout

Maximum

0.03 mm (0.0012 in.)

No. 2 camshaft cam lobe height

Standard Minimum

44.666 to 44.766 mm (1.7585 to 1.7624 in.) 44.52 mm (1.7528 in.)

No. 2 camshaft No. 1 journal diameter

34.449 to 34.465 mm (1.3563 to 1.3569 in.)

No. 2 camshaft other journal diameter

22.949 to 22.965 mm (0.9035 to 0.9041 in.)

Camshaft thrust clearance

Standard Maximum

0.040 to 0.095 mm (0.0016 to 0.0037 in.) 0.11 mm (0.0043 in.)

Camshaft oil clearance

Standard Maximum

0.035 to 0.072mm (0.0014 to 0.0028 in.) 0.08 mm (0.0031 in.)

Camshaft bearing cap setting ring pin protrusion height

8.5 to 9.5 mm (0.335 to 0.374 in.)

Connection rod thrust clearance

Standard Maximum

0.16 to 0.36 mm (0.0063 to 0.0142 in.) 0.36 mm (0.0142 in.)

Connecting rod oil clearance

Standard Maximum

0.012 to 0.038 mm (0.00047 to 0.0015 in.) 0.058 mm (0.0028 in.)

Crankshaft thrust clearance

Standard Maximum

0.09 to 0.19 mm (0.0035 to 0.0075 in.) 0.03 mm (0.0118 in.)

Cylinder block warpage

Maximum

0.05 mm (0.0020 in.)

Cylinder bore diameter

Standard Difference limit

75.000 to 75.013 mm (2.9528 to 2.9533 in.) 0.10 mm (0.0039 in.)

Piston diameter

74.935 to 74.945 mm (2.9502 to 2.9506 in.)

Piston pin hole diameter at 20°C (68°F)

18.013 to 18.016 mm (0.7092 to 0.7093 in.)

Piston pin diameter

18.001 to 18.004 mm (0.7087 to 0.7088 in.)

Piston pin oil clearance

Standard Maximum

0.009 to 0.015 mm (0.0004 to 0.0006 in.) 0.050 mm (0.0020 in.)

Piston clearance

Standard

0.045 to 0.068 mm (0.0018 to 0.0027 in.)

Connecting misalignment

Maximum

0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

Connecting rod twist

Maximum

0.05 mm (0.0020 in.) per 100 mm (3.94 in.)

Piston ring groove clearance

No. 1 No. 2

0.03 to 0.07 mm (0.0012 to 0.0028 in.) 0.02 to 0.06 mm (0.0008 to 0.0024 in.)

Piston ring end gap

Standard No. 1 No. 2 Oil (Side rail) Maximum No. 1 No. 2 Oil (Side rail)

0.25 to 0.35 mm (0.0098 to 0.0138 in.) 0.35 to 0.50 mm (0.0138 to 0.0197 in.) 0.10 to 0.35 mm (0.0039 to 0.0138 in.) 0.91 mm (0.0358 in.) 1.60 mm (0.0417 in.) 0.82 mm (0.0323 in.)

Connecting rod bolt diameter

Standard Maximum

6.6 to 6.7 mm (0.260 to 0.264 in.) 6.4 mm (0.252 in.)

Crankshaft circle runout

Maximum

Crankshaft main journal diameter Crankshaft main journal taper and outof-round

0.03 mm (0.0012 in.) 45.988 to 46.000 mm (1.8106 to 1.8110 in.)

Maximum

Crank pin diameter

0.02 mm (0.0008 in.) 39.992 to 40.000 mm (1.5745 to 1.5748 in.)

Crank pin taper and out-of- round

Maximum

0.02 mm (0.0008 in.)

Crankshaft timing sprocket diameter (w/ chain)

Standard Minimum

51.72 mm (2.0362 in.) 50.5 mm (1.988 in.)

Crankshaft bearing cap set bolt diameter

Standard Minimum

7.3 to 7.5 mm (0.287 to 0.295 in.) 7.2 mm (0.283 in.)


SERVICE SPECIFICATIONS – 1NZ-FE ENGINE MECHANICAL Crankshaft oil clearance

Standard Maximum

SS–7

0.01 to 0.023 mm (0.0004 to 0.0009 in.) 0.07 mm (0.0028 in.)

SS


SS–8

SERVICE SPECIFICATIONS – 1NZ-FE ENGINE MECHANICAL

TORQUE SPECIFICATIONS Part tightened

SS

N*m

kgf*cm

ft.*lbf

Spark plugs x Cylinder head assembly

18

184

13

Camshaft bearing cap No. 2 x Cylinder head assembly

13

129

9.4

Camshaft bearing cap No. 1 x Cylinder head assembly

23

235

17

Camshaft No. 2 x Camshaft timing sprocket

64

653

47

Screw plug x Oil pump assembly

5

153

11

Chain vibration damper No. 1 x Cylinder head & block

9.0

92

80 in.*lbf

Chain tensioner slipper x Cylinder block assembly

9.0

92

80 in.*lbf

Camshaft timing gear assembly x Camshaft

64

653

47

Stud bolt x Cylinder head assembly

Bolt A

10

102

7.4

Bolt B

4.0

41

35 in.*lbf

Bolt C

10

102

7.4

Bolt D

9.0

92

80 in.*lbf

Taper screw plug x Cylinder head assembly

30

306

22

Taper screw plug x Cylinder head assembly

44

449

33

19 9.0

194 92

14 80 in.*lbf

Fuel delivery pipe subassembly x Cylinder head assembly

Bolt A Bolt B

Cylinder head assembly x Harness bracket

13

131

9.5

Engine coolant temperature sensor x Cylinder head assembly

20

204

15

Camshaft position sensor x Cylinder head assembly

8.0

82

71 in.*lbf

Booster vacuum tube x Cylinder head assembly

9.0

92

80 in.*lbf

Exhaust manifold x Cylinder head assembly

27

275

20

Exhaust manifold heat insulator No. 1 x Exhaust manifold

8.0

82

71 in.*lbf

29 Turn 90° Turn 90°

300 Turn 90° Turn 90°

22 Turn 90° Turn 90°

Manifold support bracket x Cylinder block & exhaust manifold

44

449

33

Exhaust front pipe assembly x Exhaust manifold

43

439

32

Cylinder head assembly x Wire harness

13

133

10

1st 2nd 3rd

Cylinder head assembly x Cylinder block assembly

Cylinder head assembly x Water by-pass pipe No. 1

90

92

80 in.*lbf

Oil level gauge guide x Cylinder block assembly

90

92

80 in.*lbf

Intake manifold x Cylinder head assembly

30

306

22

Water filler sub-assembly x Throttle with motor body assembly

7.5

76

66 in.*lbf

22

224

16

5.0 5.0 11 5.0

51 51 112 51

44 in.*lbf 44 in.*lbf 8.1 44 in.*lbf

Connecting rod assembly x Connecting rod cap

15

153

11

Oil pan sub-assembly x Stud bolt

5.0

51

44 in.*lbf

Cylinder block assembly x Oil pan sub-assembly

24

245

18

Oil pan sub-assembly x Oil strainer

11

112

8.1

Oil pan sub-assembly x Oil pan sub-assembly No. 2

9.0

92

80 in.*lbf

Cylinder block assembly x Crankshaft bearing cap Stud bolts x Cylinder block assembly

Bolt A Bolt B Bolt C Bolt D

Oil pan sub-assembly No. 2 x Drain plug

38

382

28

Oil pan sub-assembly x Oil filter union

30

306

22

Cylinder head assembly x Camshaft position sensor

8.0

82

71 in.*lbf

Cylinder block assembly x Chain tensioner assembly No. 1

9.0

92

80 in.*lbf

32 11 11 24 24

326 112 112 245 245

24 8.1 8.1 18 18

oil pump assembly x Cylinder head & block

Bolt A Bolt B Bolt C Nut D Bolt E


SS–9

SERVICE SPECIFICATIONS – 1NZ-FE ENGINE MECHANICAL Part tightened Oil pump assembly x Water pump assembly

N*m

kgf*cm

ft.*lbf

11

112

8.1

Transverse engine mounting bracket x Cylinder head & block

55

561

41

Water pump assembly x Pump pulley

15

153

11

Crankshaft damper sub-assembly x Crankshaft

128

1305

95

Camshaft timing oil control valve x Cylinder head assembly

7.5

76

66 in.*lbf

Cylinder head cover sub-assembly x Cylinder head assembly

10

102

7.0

Ventilation valve sub-assembly x Cylinder head cover sub-assembly

27

275

20

Crankshaft position sensor x Oil pump assembly

7.5

76

66 in.*lbf

Water inlet x Cylinder block assembly

9.0

92

80 in.*lbf

Oil pressure switch x Cylinder block assembly

15

153

11

Knock sensor x Cylinder block assembly

20

204

15

Front wheel hub nut

103

1050

912

Battery terminal x Cable

5.4

55

48 in.*lbf

Battery x Battery clamp

3.5

36

31 in.*lbf

Cowl top panel outer x Body

6.5

66

57 in.*lbf

Air cleaner hose No.1 x Throttle with motor body assembly

4.0

41

35 in.*lbf

Air cleaner case with air cleaner inlet No.1 x Air cleaner bracket

7.8

80

69 in.*lbf

Air cleaner bracket x Body

19

194

14

Battery carrier x Body

17

173

13

Drive plate and torque converter clutch setting bolt x Drive plate and ring gear sub-assembly

27

275

20

Front suspension crossmember x Body

Engine mounting insulator RH x Body (for Hatchback)

Bolt A

70

714

52

Bolt B

160

1631

118

Bolt C

95

969

70

Bolt A

45

459

33

52

530

38

Engine mounting insulator RH x Body (for Sedan)

Bolt B

52

530

38

Engine mounting insulator LH x Engine mounting bracket LH

52

530

38

Front suspension crossmember sub-assembly x Engine moving control rod

120

1224

89

Oxygen sensor wiring bracket x Cylinder head sub-assembly

60

612

44

Radio setting condenser x Cylinder head sub-assembly

40

408

30

Water filler sub-assembly x Radiator sub-assembly

7.5

76

66 in.*lbf

1 st

49

500

38

2 nd

Turn 90°

Turn 90°

Turn 90°

Automatic transaxle assembly x Engine block sub-assembly

30

301

22

Drive plate and ring gear sub-assembly x Crankshaft

88

900

65

Water by-pass pipe No.1 x Cylinder head sub-assembly and block sub-assembly

9.0

92

80 in.*lbf

Booster vacuum tube x Cylinder head sub-assembly

9.0

92

80 in.*lbf

Wire harness clamp bracket x Cylinder head sub-assembly

10

102

89 in.*lbf

Drive shaft heat insulator sub-assembly x Cylinder block subassembly

18

183

13

Flywheel sub-assembly x Crankshaft

SS


SERVICE SPECIFICATIONS – 1NZ-FE FUEL

SS–9

1NZ-FE FUEL SERVICE DATA Fuel pressure

Standard fuel pressure

304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44.1 to 49.7 psi)

Fuel pressure : at fuel while the engine idles

Standard fuel pressure

304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44.1 to 49.7 psi)

Fuel pressure : at fuel pressure remains for 5 minutes after engine has stopped

Standard fuel pressure

147 kPa (1.5 kgf/cm2, 21 psi) or more

Standard resistance

11.6 to 12.4 Ωat 20°C (68°F)

Injection volume

47 to 58 cm3(2.9 to 3.5 cu in.) per 15 seconds Connect

Difference between each injector

11 cm3(0.6 cu in.) or less

Fuel injector assembly

Fuel pump

Fuel drop

1 drop or less every 12 minutes

Standard resistance

0.2 to 3.0 Ω at 20°C (68°F)

SS


SS–10

SERVICE SPECIFICATIONS – 1NZ-FE FUEL

TORQUE SPECIFICATIONS Part tightened

N*m

kgf*cm

ft.*lbf

19 9.0

194 92

14 80 in.*lbf

Cylinder head cover sub-assembly x Cylinder head assembly

10

102

7.0

Cylinder head cover sub-assembly x Wire harness bracket

13

133

9.6

Fuel tank assembly x Floor panel

14

146

10

Fuel tank cover vent case sub-assembly x Floor panel

5.4

55

48 in.*lbf

Front heat insulator No. 4 x Floor panel

5.4

55

48 in.*lbf

Fuel delivery pipe sub-assembly x Cylinder head assembly

SS

Battery negative battery x Battery negative cable

bolt A bolt B

5.4

55

48 in.*lbf


SS–10

SERVICE SPECIFICATIONS – 1NZ-FE EMISSION CONTROL

1NZ-FE EMISSION CONTROL SERVICE DATA

SS

VSV

Standard resistance 1-2

23 to 26 Ω at 20°C (68°F)

Air fuel ratio sensor

Standard resistance 1-2 1-4

1.8 to 3.4 Ω at 20°C (68°F) 10 kΩ or higher

Heated oxygen sensor

Standard resistance 1-2 1-4

11 to 16 Ω at 20°C (68°F) 10 kΩ or higher


SS–11

SERVICE SPECIFICATIONS – 1NZ-FE EMISSION CONTROL

TORQUE SPECIFICATIONS Part Tightened

N*m

kgf*cm

ft.*lbf

Canister x Floor assembly

19

194

14

Ventilation valve x Cylinder head cover sub-assembly

27

275

20

Air fuel ratio sensor x Exhaust manifold assembly

44

449

32

Heated oxygen sensor x Front exhaust pipe

44

449

32

Battery negative terminal x Battery negative cable

5.4

55

48 in.*lbf

SS


SERVICE SPECIFICATIONS – 1NZ-FE EXHAUST

SS–11

1NZ-FE EXHAUST SERVICE DATA Compression spring

Minimum length Front side

40.5 mm (1.594 in.)

Minimum length Rear side

38.5 mm (1.516 in.))

SS


SS–12

SERVICE SPECIFICATIONS – 1NZ-FE EXHAUST

TORQUE SPECIFICATIONS Part Tightened

SS

N*m

kgf*cm

ft.*lbf

Exhaust front pipe assembly x Exhaust manifold

43

439

32

Heated oxygen sensor (for sensor 2) x Exhaust front pipe assembly

44

449

32

Battery negative terminal x Battery negative cable

5.4

55

48 in.*lbf


SS–12

SERVICE SPECIFICATIONS – 1NZ-FE COOLING

1NZ-FE COOLING SERVICE DATA Thermostat

Cooling fan relay No.2

SS Cooling fan motor

Cooling fan relay

Valve opening temperature

80 to 84°C (176 to 183°F)

Valve lift

8.5 mm (0.335 in.) or more at 95°C (203°F)

Standard resistance B5 - B8

10 kΩ or higher

Standard resistance B5 - B8

Below 1 Ω (Apply battery voltage between terminals B6 and B7)

w/ A/C

7.3 to 9.3A (at 12V)

w/o A/C

5.2 to 8.2A (at 12V)

3-4

Below 1Ω

3-4(When battery voltage applied to terminals 1 and 2)

10KΩ or higher

3-5

10KΩ or higher

3-5 (When battery voltage applied to terminals 1 and 2)

Below 1Ω

Standard valve (for brand new cap)

93.3 to 122.7 kpa (0.95 to 1.25 kgf/cm2, 13.5 to 17.8 psi)

Minimum standard valve (after using cap)

78.5 kpa (0.8 kgf/cm2, 11.4 psi)

at 20°C (68°F)

1.17 to 1.43 Ω

Radiator cap sub-assembly

Cooling fan resistor


SS–13

SERVICE SPECIFICATIONS – 1NZ-FE COOLING

TORQUE SPECIFICATIONS Part tightened

N*m

kgf*cm

ft.*lbf

Water pump assembly x Oil pump assembly

11

112

8.1

Water pump pulley x Water pump assembly

15

153

11

Water inlet x Radiator hose

9.0

92

80 in.*lbf

Negative battery terminal x Cable

5.4

55

48 in.*lbf

Air cleaner hose No.1 x Throttle with motor body assembly

4.0

41

35 in.*lbf

Air cleaner case with air cleaner inlet No.1 x Air cleaner bracket

7.8

80

69 in.*lbf

Hood lock assembly x Radiator support sub-assembly upper

7.5

76

66 in.*lbf

Radiator support sub-assembly upper x Body

5.5

56

49 in.*lbf

Cooling fan resistor x Body

5.1

52

45 in.*lbf

SS


SERVICE SPECIFICATIONS – 1NZ-FE LUBRICATION

SS–13

1NZ-FE LUBRICATION SERVICE DATA 29 kPa (0.3 kgf/cm2, 4.3 psi) or more at idling oil pressure

Standard oil pressure

150 to 550 kPa (1.5 to 5.6 kgf/cm2, 22 to 80 psi) or more at 3,000 rpm

Oil pump rotor set

Standard tip clearance Maximum tip clearance Standard body clearance Maximum body clearance

0.060 to 0.180 mm (0.0024 to 0.0071 in.) 0.28 mm (0.0110 in.) 0.250 to 0.325 mm (0.0098 to 0.0128 in.) 0.425 mm (0.0167 in.)

SS


SS–14

SERVICE SPECIFICATIONS – 1NZ-FE LUBRICATION

TORQUE SPECIFICATIONS Part tightened

SS

N*m

kgf*cm

ft.*lbf

Oil pressure switch x Cylinder block assembly

15

153

11

Oil pump cover x Oil pump relief valve plug

25

255

18

oil pump cover x Oil pump assembly

Bolt Screw

8.8 10

90 105

78 in.*lbf 7.6

Oil pump assembly x Cylinder head & block

Bolt A Bolt B Bolt C Nut D Bolt E

32 11 11 24 24

326 112 112 245 245

24 8.1 8.1 18 18

5

561

41

128

1,305

95

45 52 52

459 530 530

33 38 38

Engine mounting insulator sub-assembly RH x Transverse engine engine mounting bracket & Body (for Sedan)

52

530

38

Oil pan drain plug

37.5

382

27.6

Oil filter sub-assembly

13

133

9.5

Oil pan drain plug

37.5

382

27.6

Oil filter sub-assembly

13

133

9.5

Transverse engine engine mounting bracket x Cylinder block assembly Crankshaft damper sub-assembly x Crankshaft Engine mounting insulator sub-assembly RH x Transverse engine engine mounting bracket & Body (for Hatchback)

Bolt A Bolt B Nut


SS–14

SERVICE SPECIFICATIONS – 1NZ-FE IGNITION

1NZ-FE IGNITION SERVICE DATA Standard resistance Recommended spark plug Spark plug

SS

Maximum electrode gap Electrode gap

10 M Ωor more SK16R 11 DENSO made IFR5A 11 NGK made 1.3 mm (0.051 in.) for used spark plug 1.0 to 1.1mm (0.039 to 0.043 in.) for new spark plug


SS–15

SERVICE SPECIFICATIONS – 1NZ-FE IGNITION

TORQUE SPECIFICATIONS Part tightened

N*m

kgf*cm

ft.*lbf

Spark plugs x Cylinder head assembly

18

184

13

Ignition coil x Cylinder head cover

9.0

92

80 in.*lbf

Cylinder head cover No. 2 x Cylinder head cover

7.0

71

62 in.*lbf

SS


SERVICE SPECIFICATIONS – 1NZ-FE STARTING

SS–15

1NZ-FE STARTING SERVICE DATA for 0.8 kW Starter assembly

Standard current

Starter relay

Standard resistance 3-5

Standard resistance 3-4 ACC cut relay Standard resistance 3-5 AM2 fuse

IG2 relay

Ignition relay

Ignition or starter switch assembly.

Starter armature assembly commutator diameter Starter armature assembly undercut portion

Starter yoke assembly resistance

Brush length Starter brush holder assembly resistance Magnet starter switch assembly resistance

10 kΩ or higher Below 1 Ω 10 kΩ or higher (when battery voltage applied to terminals 1 and 2) Below 1 Ω(when battery voltage applied to terminals 1 and 2) 10 kΩ or higher Below 1 Ω

Standard resistance B1 - C1

Below 1 Ω 10 kΩ or higher

Standard resistance B4 - C1

Standard resistance 3-5

Below 1 Ω (Apply battery voltage between terminals B2 and B3) Below 1 Ω(when battery voltage applied to terminals 1 and 2) 10 kΩ or higher

Standard resistance Between all terminals

10 kΩ or higher (LOCK)

Standard resistance 2-4

Below 1 Ω (ACC)

Standard resistance 1-2-4 Standard resistance 5-6

Standard resistance 5-6-7

Starter armature assembly commutator circumference runout

Below 1 Ω(when battery voltage applied to terminals 1 and 2)

Standard resistance 1-2

Standard resistance 1-3-4

Starter armature assembly resistance

90 A or less at 11.5 V

Below 1 Ω (ON)

Below 1 Ω (START)

Segments

Below 1 Ω

Commutator - Armature coil

10kΩ or higher

Maximum runout

0.05 mm (0.0020 in.)

Standard diameter