Electrical Section

6-1 SPECIFICATIONS AND SERVICE DATA
1. Engine Electrical
1. Engine Electrical
A: SPECIFICATIONS
Item Designation
Type Reduction type
MT AT
Model
TN128000-8311 TN128000-8321
Manufacturer NIPPONDENSO TENNESSEE
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
Voltage 11 V
No-load Current 90 A or less
Starter characteristics Rotating
3,000 rpm or more 2,900 rpm or more
speed
Voltage 8V
Current 280 A or less 370 A or less
Load
characteristics Torque 9.8 N⋅m (1.0 kg-m, 7.2 ft-lb) 13.7 N⋅m (1.4 kg-m, 10.1 ft-lb)
Rotating
900 rpm or more 880 rpm or more
speed
Voltage 5V
Lock
Current 800 A or less 1,050 A or less
characteristics
Torque 27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) or more
Type Rotating-field three-phase type, Voltage regulator built-in type
Model LR185-701H
Manufacturer HITACHI AUTOMOTIVE PRODUCTS
Voltage and output 12 V — 85 A
Polarity on ground side Negative
Generator Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
1,500 rpm — 35 A or more
Output current 2,500 rpm — 62 A or more
5,000 rpm — 82 A or more
Regulated voltage 14.5+0.3
−0.4 V [20°C (68°F)]
Model F-569-01R
Manufacturer Diamond
Ignition Primary coil resistance 0.69 Ω±10%
coil Secondary coil resistance 21.0 kΩ±15%
Insulation resistance between
More than 10 MΩ
primary terminal and case
RC10YC4 .......... CHAMPION
Type and manufacturer BKR6E-11 .......... NGK
Spark Alternate ( K20PR-U11 .......... NIPPONDENSO )
plug
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0 — 1.1 (0.039 — 0.043)
2
COMPONENT PARTS 6-1
1. Starter
1. Starter
1. MT: 128000-8311
B6M0412A
쎻
1 Front ball bearing 쎻
13 Starter housing
쎻
2 Armature 쎻
14 Overrunning clutch
쎻
3 Rear ball bearing 쎻
15 Steel ball
쎻
4 O-ring 쎻
16 Spring
쎻
5 Yoke 쎻
17 Retainer
쎻
6 Brush spring 쎻
18 Roller
쎻
7 Brush holder 쎻
19 Idle gear
쎻
8 End frame 쎻
20 Nut
쎻
9 Screw & washer 쎻
21 Spring washer
쎻
10 Cover
쎻
22 Magnet switch
쎻
11 Through bolt
쎻
23 Nut
쎻
12 Screw & washer
3
6-1 COMPONENT PARTS
1. Starter
2. AT: 128000-8321
B6M0413A
쎻
1 Front ball bearing 쎻
13 Starter housing
쎻
2 Armature 쎻
14 Overrunning clutch
쎻
3 Rear ball bearing 쎻
15 Steel ball
쎻
4 O-ring 쎻
16 Spring
쎻
5 Yoke 쎻
17 Retainer
쎻
6 Brush spring 쎻
18 Roller
쎻
7 Brush holder 쎻
19 Idle gear
쎻
8 End frame 쎻
20 Nut
쎻
9 Cover 쎻
21 Spring washer
쎻
10 Screw & washer
쎻
22 Magnet switch
쎻
11 Through bolt
쎻
23 Nut
쎻
12 Screw & washer
4
COMPONENT PARTS 6-1
2. Generator
2. Generator
B6M0414A
쎻
1 Pulley nut 쎻
13 Bolt
쎻
2 Pulley 쎻
14 Brush holder ASSY
쎻
3 Front cover ASSY 쎻
15 Rear cover
쎻
4 Ball bearing 쎻
16 BAT. terminal
쎻
5 Bearing retainer 쎻
17 Nut
쎻
6 Screw 쎻
18 Bolt
쎻
7 Rotor 쎻
19 Through bolt
쎻
8 Stator coil
쎻
9 IC regulator ASSY Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.1 — 4.4 (0.32 — 0.45, 2.3 — 3.3)
쎻
10 Condenser
T2: 63.7 — 83.4 (6.5 — 8.5, 47.0 — 61.5)
쎻
11 Diode ASSY
쎻
12 Bolt
5
6-1 SERVICE PROCEDURE
1. Starter
1. Starter
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Disconnect connector and terminal from starter.

3) Remove starter from transmission.
4) Installation is in the reverse order of removal.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
G2M0309
B: TEST
1. MAGNETIC SWITCH
CAUTION:
쐌 The following magnetic switch tests should be per-
formed with specified voltage applied.
쐌 Each test should be conducted within 3 to 5 sec-
onds. Power to be furnished should be one-half the
rated voltage.
1) Pull-in test
Connect two battery negative leads onto magnetic switch
body and terminal C respectively. Then connect battery
positive lead onto terminal 50. Pinion should extend when
lead connections are made.
B6M0415A
2) Holding-in test
Disconnect lead from terminal C with pinion extended. Pin-
ion should be held in the extended position.
B6M0416A
6
SERVICE PROCEDURE 6-1
1. Starter
3) Return test
Connect two battery negative leads onto terminal 50 and
onto switch body respectively. Then connect battery posi-
tive lead onto terminal C. Next, disconnect lead from ter-
minal 50. Pinion should return immediately.
B6M0417A
2. PERFORMANCE TEST
The starter is required to produce a large torque and high
rotating speed, but these starter characteristics vary with
the capacity of the battery. It is therefore important to use
a battery with the specified capacity whenever testing the
starter.
The starter should be checked for the following three items:
1. No-load test
Measure the maximum rotating speed and current under a
no-load state.
2. Load test
Measure the magnitude of current needed to generate the
specified torque and rotating speed.
3. Stall test
Measure the torque and current when the armature is
locked.
1) No-load test
Run single starter under no-load state, and measure its
rotating speed, voltage, and current, using the specified
battery. Measured values must meet the following stan-
dards:
No-load test (Standard):
Voltage/Current
11 V/90 A, or more
Rotating speed
B6M0418A TN128000-8311: 3,000 rpm, or more
TN128000-8321: 3,350 rpm, or more
7
1. Starter
2) Load test (For reference)

Perform this test to check maximum output of starter. Use
test bench which is able to apply load (brake) to starter.
Measure torque value and rotating speed under the speci-
fied voltage and current conditions while controlling brak-
ing force applied to starter.
CAUTION:
Change engagement position of overrunning clutch
and make sure it is not slipping.
B6M0419A
Load test (Standard):
TN128000-8311
Voltage/Load
8 V/9.8 N⋅m (1.0 kg-m, 7.2 ft-lb)
Current/Speed
280 A max./900 rpm min.
TN128000-8321
Voltage/Load
8 V/13.7 N⋅m (1.4 kg-m, 10.1 ft-lb)
Current/Speed
370 A, or less/880 rpm, or more
3) Stall test
Using the same test equipment used for load test, apply
brake to lock starter armature. Then measure voltage,
current, and torque values.
Measured values must meet the following standard.
Stall test (Standard):
TN128000-8311
Voltage/Current
5 V/800 A, or less
B6M0420A Torque
27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) min.
TN128000-8321
Voltage/Current
5 V/1,050 A, or less
Torque
27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) min.
NOTE:
Low rotating speed or excessive current during no-load test
may be attributable to high rotating resistance of starter
due to improper assembling.
Small current and no torque during stall test may be attrib-
utable to excessive contact resistance between brush and
commutator; whereas, normal current and insufficient
torque may be attributable to shorted commutator or poor
insulation.
Starter can be considered normal if it passes no-load and
stall tests; therefore, load test may be omitted.
8
1. Starter
C: DISASSEMBLY
1) Disconnect lead wire from magnetic switch.
B6M0421A
2) Remove through-bolts from end frame.
B6M0422A
3) Remove yoke from magnetic switch.
B6M0423A
4) Remove screws securing end frame to brush holder.
B6M0424A
5) Separate yoke from end frame.
B6M0425A
9
1. Starter
6) Remove brush by lifting up positive (+) side brush

spring using long-nose pliers.
CAUTION:
Be careful not to damage brush and commutator.
B6M0426A
7) Remove armature from yoke.

CAUTION:
Be careful not to drop armature.
B6M0427A
8) Remove screws securing magnetic switch to housing.
B6M0428A
9) Remove housing from magnetic switch.
B6M0429A
10) Remove clutch from housing.
B6M0430A
10
1. Starter
11) Take out steel ball from clutch.

CAUTION:
Be careful not to lose steel ball.
B6M0431A
12) Remove idle gear from housing.
B6M0432A
13) Remove retainer and roller from housing.

CAUTION:
Be careful not to drop retainer and roller.
B6M0433A
14) Remove coil spring from magnetic switch.
B6M0434A
D: INSPECTION
1. ARMATURE
1) Check commutator for any sign of burns of rough sur-
faces or stepped wear. If wear is of a minor nature, correct
it by using sand paper.
11
1. Starter
2) Run-out test
Check the commutator run-out and replace if it exceeds the
limit.
Commutator run-out:
Standard
0.02 mm (0.0008 in), or less
Service limit
Less than 0.05 mm (0.0020 in)
G6M0038
3) Depth of segment mold

Check the depth of segment mold.
Depth of segment mold:
0.6 mm (0.024 in)
Limit
0.2 mm (0.008 in)
G6M0039
4) Armature short-circuit test

Check armature for short-circuit by placing it on growler
tester. Hold a hacksaw blade against armature core while
slowly rotating armature. A short-circuited armature will
cause the blade to vibrate and to be attracted to core. If the
hacksaw blade is attracted or vibrates, the armature, which
is short-circuited, must be replaced or repaired.
G6M0040
5) Armature ground test

Using circuit tester, touch one probe to the commutator
segment and the other to shaft. There should be no conti-
nuity. If there is a continuity, armature is grounded.
Replace armature if it is grounded.
G6M0041
2. YOKE
Make sure pole is set in position.
B6M0435
12
1. Starter
3. OVERRUNNING CLUTCH
Inspect teeth of pinion for wear and damage. Replace if it
is damaged. Rotate pinion in direction of rotation (clock-
wise). It should rotate smoothly. But in opposite direction,
it should be locked.
CAUTION:
Do not clean overrunning clutch with oil to prevent
grease from flowing out.
B6M0436
4. BRUSH AND BRUSH HOLDER

1) Brush length
Measure the brush length and replace if it exceeds the
service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard 15 mm (0.59 in)
Service limit 10 mm (0.39 in)
B6M0437
2) Brush movement
Be sure brush moves smoothly inside brush holder.
3) Insulation resistance of brush holder

Be sure there is no continuity between brush holder and its
plate.
B6M0438
4) Brush spring force

Measure brush spring force with a spring scale. If it is less
than the service limit, replace brush spring.
Brush spring force:
Standard
18.6 N (1.9 kg, 4.2 lb) (when new)
Service limit
6.9 N (0.7 kg, 1.5 lb)
13
1. Starter
5. BEARING
1) Rotate bearing by hand; no binding should exist.
2) Rotate bearing rapidly; no abnormal noise should be
heard.
B6M0439A
E: ASSEMBLY
Assembly is in the reverse order of disassembly proce-
dures. Observe the following:
1) Before assembling, lubricate disassembled parts at the
points shown in “COMPONENT PARTS [C101] and
[C102]”.
Grease:
ESSO BEACON 325
SCHELL ALVANIA GREASE RA or equivalent
2) Assembling magnetic switch, clutch, and housing

To assemble, first install clutch to magnetic switch, then
install idle gear, and finally install clutch.
CAUTION:
쐌 Do not forget to install steel ball and coil spring to
clutch.
쐌 Attach bearing to idle gear beforehand.
B6M0470A
3) Installing armature to yoke

CAUTION:
Do not forget to put felt washer on armature shaft bear-
ing.
B6M0427A
4) Installing brushes
Assemble brush holder to yoke as shown, then assemble
two yoke-side brushes to brush holder.
B6M0471A
14
1. Starter - 2. Generator
5) Installing end frame

When assembling end frame to yoke, align notched portion
of end frame with lead wire grommet.
B6M0472A
6) Installing yoke
When installing yoke to magnetic switch, align notch of
yoke with protrusion of magnetic switch.
B6M0473A
2. Generator
G6M0095
2) Disconnect connector and terminal from generator.
G2M0088
3) Remove V-belt cover.

4) Remove front side V-belt.
G2M0286
15
1. Starter - 2. Generator
5) Installing end frame

When assembling end frame to yoke, align notched portion
of end frame with lead wire grommet.
B6M0472A
6) Installing yoke
When installing yoke to magnetic switch, align notch of
yoke with protrusion of magnetic switch.
B6M0473A
2. Generator
G6M0095
2) Disconnect connector and terminal from generator.
G2M0088
3) Remove V-belt cover.

4) Remove front side V-belt.
G2M0286
15
2. Generator
5) Remove bolts which install generator onto bracket.
G2M0090

CAUTION:
Check and adjust V-belt tension. <Ref. to 1-5 [01A0].>
G2M0090
B: DISASSEMBLY
1) Heat the portion 쎻
A of rear cover to 50°C (122°F) with
heater drier.
B6M0476A
2) Remove the four through bolts. Then insert the tip of a

flat-head screwdriver into the gap between the stator core
and front bracket. Pry then apart to disassemble.
G6M0065
3) Hold rotor with a vise and remove pulley nut.
G6M0066
16
2. Generator
CAUTION:
When holding rotor with vise, insert aluminum plates
or wood pieces on the contact surfaces of the vise to
prevent rotor from damage.
B6M0477A
4) Remove rotor from front cover.

5) Remove three screws from front cover and then bear-
ing retainer and ball bearing.
B6M0478A
6) Remove bolt which secure battery terminal bolt, and

remove rear cover. Remove nuts which secure diode plate,
and remove stator and rear cover.
B6M0479A
7) Separate diode plate from stator coil.

(1) Cut the connecting position 쎻 A of stator coil to
diode.
(2) Unsolder connection 쎻 B and throughout the lead
wire of stator coil.
B6M0480A
(3) Remove stator coil from diode plate.
B6M0481
17
2. Generator
8) Remove bolts which secure IC regulator, diode and

brush holder.
CAUTION:
Do not apply a shock or load to IC regulator cooling
fins.
B6M0482
C: INSPECTION AND REPAIR

1. ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any roughness of the
sliding surface.
Clean or polish with #500 to #600 emery paper if defective.
G6M0075
2) Slip ring outside diameter

Measure slip ring outside diameter. If slip ring is worn,
replace rotor.
Slip ring outside diameter:
Standard
27 mm (1.06 in)
Limit
26 mm (1.02 in)
B6M0483A
3) Continuity test
Check continuity between slip rings. If continuity does not
exist, replace rotor.
B6M0484A
4) Insulation test
Check continuity between slip ring and rotor core or shaft.
If continuity exists, replace rotor.
B6M0485A
18
2. Generator
5) Ball bearing
Check rear ball bearing. Replace it if it is noisy or if rotor
does not turn smoothly.
B6M0486
2. STATOR
1) Continuity test
Inspect stator coil for continuity between its terminals.
When there is no continuity between individual terminals,
cable is broken.
Replace stator coil.
G6M0078
2) Insulation test
Inspect stator coil for continuity between stator core and
each terminal. If there is continuity, replace stator coil.
G6M0079
3. BRUSH
Measure brush length. If brush is worn, replace brush
holder assembly.
Brush length ():
Standard
20.5 mm (0.807 in)
Limit
1.5 mm (0.059 in)
B6M0487A
4. DIODE ASSEMBLY
The diode consists of eight diodes, four each being located
on the positive and negative sides. The diode is necessary
to restrict current flow to one direction.
Check all diodes, for continuity. If any diode is faulty,
replace diode assembly.
B6M0488A
19
2. Generator
1) Diodes on “+” side

Continuity of proper diodes on “+” side
BAT side
Terminal (+) (−)
N, U, V and W
Continuity must
(+) —
not exist.
Continuity
(−) —
B6M0489A must exist.
2) Diodes on “−” side

Continuity of proper diodes on “−” side
“E” side
Terminal (+) (−)
N, U, V and W
Continuity must
(+) —
exist.
Continuity
(−) —
B6M0490A must not exist.
CAUTION:
Never use a high tension insulation tester, such as a
meggar as it will damage diodes with its high tension.
5. IC REGULATOR
1) Compose a circuit diagram as shown in figure.
쎻1 Voltage meter: 0 to 30 V
쎻2 Switch 1
쎻3 Variable DC power supply: Variable 0 to 20 V, 1 A or
more
쎻
4 Lamp 2
쎻
5 Lamp 1
쎻
6 Switch 3
B6M0491A 쎻
7 Switch 2
쎻
8 Plus generator: Power supply 5 to 30 V, 1 kHz
20
2. Generator
2) Check operation as shown in chart below.

Switch operation Value of Lamp operation
No. Remarks
1 2 3 voltage meter 1 2
Check initial
1 ON OFF OFF 12 V DIM ON
excitation.
ON
2 ON ON OFF 12 V or OFF Check total excitation.
BLINK
OFF When value of voltage
3 ON ON OFF 16 V or OFF meter is between 12
DIM-BLINK V and 16 V.
ON
Check connection for
4 OFF ON OFF 12 V or ON
S and B terminals.
BLINK
Check for over
5 OFF ON ON 18 V ON ON
loading of voltage.
D: ASSEMBLY
Assembly is in the reverse order of disassembly proce-
dures.
CAUTION:
쐌 When disassembling generator, replace rear ball
bearing.
쐌 When soldering starter coil to diode, do not touch
lead wire with solder for more than 5 seconds.
G6M0077
쐌 Before installing rear cover, insert pin from outside

of rear cover so that holds brush. After installing rear
cover, remove pin.
B6M0492
쐌 When installing rear cover, heat portion 쎻

A to 50°C
(122°F) with heater drier.
B6M0476A
21
3. Spark Plug
3. Spark Plug
CAUTION:
All spark plugs installed on an engine, must be of the
same heat range.
Spark plug:
CHAMPION: RC10YC4
(Alternate)
NGK: BKR6E-11
NIPPONDENSO: K20PR-U11
1) Remove spark plug cords by pulling boot, not cord itself.
2) Remove spark plugs.
3) When installing spark plugs on cylinder head, use spark
plug wrench.
Tightening torque (Spark plug):
20.6±2.9 N⋅m (2.10±0.30 kg-m, 15.19±2.14 ft-lb)
CAUTION:
The above torque should be only applied to new spark
plugs without oil on their threads.
In case their threads are lubricated, the torque should
be reduced by approximately 1/3 of the specified
torque in order to avoid their over-stressing.
4) Connect spark plug cords.
B: INSPECTION
Check electrodes and inner and outer porcelain of plugs,
noting the type of deposits and the degree of electrode
erosion.
G6M0086
1) Normal
Brown to grayish-tan deposits and slight electrode wear
indicate correct spark plug heat range.
G6M0087
22
3. Spark Plug - 4. Ignition Coil
2) Carbon fouled
Dry fluffy carbon deposits on insulator and electrode are
mostly caused by slow speed driving in city, weak ignition,
too rich fuel mixture, dirty air cleaner, etc.
It is advisable to replace with plugs having hotter heat
range.
G6M0088
3) Oil fouled
Wet black deposits show excessive oil entrance into com-
bustion chamber through worn rings and pistons or exces-
sive clearance between valve guides and stems. If same
condition remains after repair, use a hotter plug.
G6M0089
4) Overheating
White or light gray insulator with black or gray brown spots
and bluish burnt electrodes indicate engine overheating.
Moreover, the appearance results from incorrect ignition
timing, loose spark plugs, wrong selection of fuel, hotter
range plug, etc. It is advisable to replace with plugs having
colder heat range.
G6M0090
C: CLEANING AND REGAPPING

Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove carbon or
oxide deposits, but do not wear away porcelain.
If deposits are too stubborn, discard plugs.
After cleaning spark plugs, recondition firing surface of
electrodes with file. Then correct the spark plug gap using
a gap gauge.
Spark plug gap: L
G6M0091 1.0 — 1.1 mm (0.039 — 0.043 in)
4. Ignition Coil
2) Disconnect connector from ignition coil.
3) Remove ignition coil.
CAUTION:
Be sure to connect wires to their proper positions.
B6M0160 Failure to do so will damage unit.
23
3. Spark Plug - 4. Ignition Coil
2) Carbon fouled
Dry fluffy carbon deposits on insulator and electrode are
mostly caused by slow speed driving in city, weak ignition,
too rich fuel mixture, dirty air cleaner, etc.
It is advisable to replace with plugs having hotter heat
range.
G6M0088
3) Oil fouled
Wet black deposits show excessive oil entrance into com-
bustion chamber through worn rings and pistons or exces-
sive clearance between valve guides and stems. If same
condition remains after repair, use a hotter plug.
G6M0089
4) Overheating
White or light gray insulator with black or gray brown spots
and bluish burnt electrodes indicate engine overheating.
Moreover, the appearance results from incorrect ignition
timing, loose spark plugs, wrong selection of fuel, hotter
range plug, etc. It is advisable to replace with plugs having
colder heat range.
G6M0090
C: CLEANING AND REGAPPING

Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove carbon or
oxide deposits, but do not wear away porcelain.
If deposits are too stubborn, discard plugs.
After cleaning spark plugs, recondition firing surface of
electrodes with file. Then correct the spark plug gap using
a gap gauge.
Spark plug gap: L
G6M0091 1.0 — 1.1 mm (0.039 — 0.043 in)
4. Ignition Coil
2) Disconnect connector from ignition coil.
3) Remove ignition coil.
CAUTION:
Be sure to connect wires to their proper positions.
B6M0160 Failure to do so will damage unit.
23
4. Ignition Coil - 6. Ignitor
B: INSPECTION
Using accurate tester, inspect the following items, and
replace if defective.
1) Primary resistance
2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates the
presence of a short-circuit.
Specified resistance:
G6M0093
[Primary side]
Between 쎻 1 and 쎻2
0.69 Ω±10%
[Secondary side]
Between terminal No. 1 and No. 2
21.0 kΩ±15%
3) Insulation between primary terminal and case: 10 MΩ
or more.
5. Spark Plug Cord

A: INSPECTION
Check for:
1) Damage to cords, deformation, burning or rust forma-
tion of terminals
2) Resistance values of cords
Resistance value:
5.12 — 12.34 kΩ
G6M0094
6. Ignitor
G6M0095
2) Disconnect connector from ignitor.

3) Remove screws which hold ignitor onto body.
B6M0161
24
B: INSPECTION
CAUTION:
G6M0093
[Primary side]
0.69 Ω±10%
[Secondary side]
21.0 kΩ±15%
or more.
5. Spark Plug Cord

A: INSPECTION
Check for:
tion of terminals
Resistance value:
5.12 — 12.34 kΩ
G6M0094
6. Ignitor
G6M0095

B6M0161
24
B: INSPECTION
CAUTION:
G6M0093
[Primary side]
0.69 Ω±10%
[Secondary side]
21.0 kΩ±15%
or more.
5. Spark Plug Cord

A: INSPECTION
Check for:
tion of terminals
Resistance value:
5.12 — 12.34 kΩ
G6M0094
6. Ignitor
G6M0095

B6M0161
24
DIAGNOSTICS 6-1
1. Starter
1. Starter
Trouble Probable cause
Magnet switch poor contact or discontinuity
Magnet switch does not operate. of pull-in coil circuit
(no clicks are heard.)
Improper sliding of magnet switch plunger
Poor contact of magnet switch’s main con-
tact point
Layer short of armature
Starter does not start.
Contaminants on armature commutator
Magnet switch operates.
(clicks are issued.) High armature mica
Improper grounding of yoke field coil
Insufficient carbon brush length
Insufficient brush spring pressure
Worn pinion teeth
Failure of pinion gear to engage ring gear Improper sliding of overrunning clutch
Starter starts but does not crank engine.
Improper adjustment of stud bolt
Clutch slippage Faulty clutch roller spring
Poor contact of magnet switch’s main con-
tact point
Layer short of armature
Discontinuity, burning or wear of armature
commutator
Starter starts but engine cranks too slowly.
Poor grounding of yoke field coil
Insufficient brush length
Insufficient brush spring pressure
Abnormal brush wear
Starter overruns. Magnet switch coil is a layer short.
25
6-1 DIAGNOSTICS
2. Generator
2. Generator
Turn ignition switch ON
(engine OFF).
왔
NO
Check if charge bulb 왘
Disconnect generator
comes on. body harness
connector.
YES
왔 왔
NO
Turn ignition switch to Check if charge bulb 왘
Replace charge bulb.
“START.” (engine starts.) comes on when terminal
(L) of body harness
connector is grounded.
YES
왔
Check IC regulator.
Check positive terminal
of diode.
왔
Check if charge bulb is YES (Remains ON or blinks.)
왘
Check or replace fan belt.
OFF while engine idles. Check generator.
Check S or BAT terminal for improper
NO contact.
왔
Measure VB* of battery 15.5 V is less than VB.
왘
Replace IC regulator
while running engine at assembly.
1,500 rpm.
VB is less 12.5 V is less than or equal to VB, and

than 12.5 V. VB is less than or equal to 15.5 V.
왔 왔
Check IC regulator as a Turn light switch ON Check if charge bulb NO
왘 왘
No problems
single unit. while engine idles. comes on.
YES
왔
Check diode assembly.
*: Terminal voltage
26
6-2 SPECIFICATIONS
1. Body Electrical
1. Body Electrical
A: SPECIFICATIONS
Reserve capacity 82 minutes (MT), 100 minutes (AT)
Battery
Cold cranking ampere 430 amperes (MT), 490 amperes (AT)
Fuse 10 A, 15 A, 20 A
Speedometer Electric pulse type
Tachometer Electric impulse type
Water temperature gauge Thermistor cross coil type
Fuel gauge Resistance cross coil type
Charge indicator light 12 V — 1.4 W
Brake fluid level warning/parking brake indicator light 12 V — 1.4 W
AT oil temperature warning light (AWD only) 12 V — 1.4 W
A.B.S. warning light 12 V — 1.4 W
CHECK ENGINE warning light
12 V — 1.4 W
(Malfunction indicator lamp)
Combination Oil pressure warning light 12 V — 1.4 W

meter AIRBAG system warning light 12 V — 1.4 W
Low fuel warning light 12 V — 3 W
FWD indicator light 12 V — 1.4 W
TCS warning light 12 V — 1.4 W
TCS indicator light 12 V — 1.4 W
Turn signal indicator light 12 V — 1.4 W (2 pieces)
Seat belt warning light 12 V — 1.4 W
Door open warning light 12 V — 1.4 W
Headlight beam indicator light 12 V — 1.4 W
12 V — 3 W (2 pieces)
Meter illumination light
12 V — 3.4 W (4 pieces)
Headlight 12 V — 60/55 W (Halogen)
Front clearance light 12 V — 5 W
Front 12 V — 21 W
Turn signal light
Rear 12 V — 21 W
Tail/Stop light 12 V — 5/21 W
Back-up light 12 V — 21 W
12 V — 18 W (SEDAN), 12 V — 13 W
High-mount stop light
(WAGON)
License plate light 12 V — 5 W
Room light 12 V — 8 W
Trunk room light (SEDAN) 12 V — 5 W
Luggage room light (WAGON) 12 V — 5 W
Spot light 12 V — 8 W (2 pieces)
Glove box light 12 V — 3.4 W
Ash tray illumination light 12 V — 1.7 W
Selector lever illumination light (AT model) 12 V — 1.7 W
2
SPECIFICATIONS 6-2
1. Body Electrical
Front wiper
Input 12 V — 54 W or less
motor
Rear wiper motor Input 12 V — 42 W or less
Front washer Pump type Centrifugal

motor Input 12 V — 36 W or less
Rear washer Pump type Centrifugal

motor Input 12 V — 36 W or less
Horn 12 V — 350 Hz
Cigarette lighter Input 12 V — 120 W
Rear window Input 12 V — 160 W

defogger Indicator light 12 V — 50 mA
3
1. Precaution - 2. Battery
1. Precaution
쐌 Before disassembling or reassembling parts, always
disconnect battery ground cable. When repairing
radio, control modules, etc. which are provided with
memory functions, record memory contents before
disconnecting battery ground cable. Otherwise, these
contents are cancelled upon disconnection.
쐌 Reassemble parts in reverse order of disassembly
procedure unless otherwise indicated.
쐌 Adjust parts to specifications contained in this
manual if so designated.
쐌 Connect connectors and hoses securely during
reassembly.
쐌 After reassembly, ensure functional parts operate
smoothly.
CAUTION:
쐌 Airbag system wiring harness is routed near the
electrical parts and switch.
쐌 All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuit.
쐌 Be careful not to damage Airbag system wiring har-
ness when servicing the ignition key cylinder.
2. Battery
1. BATTERY
1) Disconnect the positive (+) terminal after disconnecting
the negative (−) terminal of battery.
2) Remove flange nuts from battery rods and take off bat-
tery holder.
3) Remove battery.
G6M0102 Tightening torque:
3.4±1.0 N⋅m (0.35±0.1 kg-m, 2.5±0.7 ft-lb)
NOTE:
쐌 Clean battery cable terminals and apply grease to retard
the formation of corrosion.
쐌 Connect the positive (+) terminal of battery and then the
negative (−) terminal of the battery.
4
1. Precaution - 2. Battery
1. Precaution
쐌 Before disassembling or reassembling parts, always
disconnect battery ground cable. When repairing
radio, control modules, etc. which are provided with
memory functions, record memory contents before
disconnecting battery ground cable. Otherwise, these
contents are cancelled upon disconnection.
쐌 Reassemble parts in reverse order of disassembly
procedure unless otherwise indicated.
쐌 Adjust parts to specifications contained in this
manual if so designated.
쐌 Connect connectors and hoses securely during
reassembly.
쐌 After reassembly, ensure functional parts operate
smoothly.
CAUTION:
쐌 Airbag system wiring harness is routed near the
electrical parts and switch.
쐌 All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuit.
쐌 Be careful not to damage Airbag system wiring har-
ness when servicing the ignition key cylinder.
2. Battery
1. BATTERY
1) Disconnect the positive (+) terminal after disconnecting
the negative (−) terminal of battery.
2) Remove flange nuts from battery rods and take off bat-
tery holder.
3) Remove battery.
G6M0102 Tightening torque:
3.4±1.0 N⋅m (0.35±0.1 kg-m, 2.5±0.7 ft-lb)
NOTE:
쐌 Clean battery cable terminals and apply grease to retard
the formation of corrosion.
쐌 Connect the positive (+) terminal of battery and then the
negative (−) terminal of the battery.
4
2. Battery
B: INSPECTION
1. BATTERY
1) External parts
Check for the existence of dirt or cracks on the battery
case, top cover, vent plugs, and terminal posts. If
necessary, clean with water and wipe with a dry cloth.
Apply a thin coat of grease on the terminal posts to prevent
corrosion.
2) Electrolyte level
Check the electrolyte level in each cell. If the level is below
MIN LEVEL, bring the level to MAX LEVEL by pouring dis-
tilled water into the battery cell. Do not fill beyond MAX
LEVEL.
WARNING:
쐌 Electrolyte has toxicity; be careful handling the
fluid.
쐌 Avoid contact with skin, eyes or clothing. Especially
at contact with eyes, blush with water for 15 minutes
and get prompt medical attention.
쐌 Batteries produce explosive gasses. Keep sparks,
flame, cigarettes away.
쐌 Ventilate when charging or using in enclosed space.
쐌 For safety, in case an explosion does occur, wear
eye protection or shield your eyes when working near
any battery. Never lean over a battery.
쐌 Do not let battery fluid contact eyes, skin, fabrics, or
paint-work because battery fluid is corrosive acid.
쐌 To lessen the risk of sparks, remove rings, metal
watch-bands, and other metal jewelry. Never allow
metal tools to contact the positive battery terminal and
anything connected to it while you are at the same time
in contact with any other metallic portion of the vehicle
because a short circuit will be caused.
5
2. Battery
3) Specific gravity of electrolyte

Measure specific gravity of electrolyte using a hydrometer
and a thermometer.
Specific gravity varies with temperature of electrolyte so
that it must be corrected at 20°C (68°F) using the follow-
ing equation:
S20 = St + 0.0007 x (t − 20)
S20:Specific gravity corrected at electrolyte tempera-
ture of 20°C (68°F)
G6M0103 St :Measured specific gravity
t :Measured temperature °C
Determine whether or not battery must be charged,
according to corrected specific gravity.
Standard specific gravity: 1.220 — 1.290 [at 20°C
(68°F)]
Measuring the specific gravity of the electrolyte in the bat-
tery will disclose the state of charge of the battery. The
relation between the specific gravity and the state of
charge is as shown in figure.
C: CHARGING
WARNING:
쐌 Do not bring an open flame close to the battery at
this time.
CAUTION:
쐌 Prior to charging, corroded terminals should be
cleaned with a brush and common baking soda solu-
tion.
쐌 Be careful since battery electrolyte overflows while
charging the battery.
쐌 Observe instructions when handling battery
charger.
쐌 Before charging the battery on vehicle, disconnect
battery ground terminal. Failure to follow this rule may
damage generator’s diodes or other electrical units.
1. NORMAL CHARGING
Charge the battery at current value specified by manufac-
turer or at approximately 1/10 of battery’s ampere hour
rating.
2. QUICK CHARGING
Quick charging is a method in which the battery is charged
in a short period of time with a relatively large current by
using a quick charger.
Since a large current flow raises electrolyte temperature,
the battery is subject to damage if the large current is used
for prolonged time. For this reason, the quick charging
must be carried out within a current range that will not
increase the electrolyte temperature above 40°C (104°F).
It should be also remembered that the quick charging is a
temporary means to bring battery voltage up to a fair value
and, as a rule, a battery should be charged slowly with a
low current.
6
2. Battery - 3. Ignition Switch
CAUTION:
쐌 Observe the items in 1. NORMAL CHARGING
[W2C1].
쐌 Never use more than 10 amperes when charging the
battery because that will shorten battery life.
3. JUDGMENT OF BATTERY IN CHARGED

CONDITION
1) Specific gravity of electrolyte is held at a specific value
in a range from 1.250 to 1.290 for more than one hour.
2) Voltage per battery cell is held at a specific value in a
range from 2.5 to 2.8 volts for more than one hour.
4. CHECK HYDROMETER FOR STATE OF CHARGE

Hydrometer indicator State of charge Required action
Green dot Above 65% Load test
Dark dot Below 65% Charge battery
Replace battery.* (If
Clear dot Low electrolyte
cranking complaint)
*: Check electrical system before replacement.
3. Ignition Switch
1. IGNITION SWITCH
1) Remove screws, separate upper column cover and
lower column cover.
2) Remove instrument panel lower cover.
B6M0236
3) Disconnect ignition switch connector from body har-

ness.
4) Using a drift and hammer, hit the torn bolt head to
loosen and remove the ignition switch.
B6M0333
5) When installing, tighten the connecting bolt until its

head twists off.
B6M0334A
7
2. Battery - 3. Ignition Switch
CAUTION:
쐌 Observe the items in 1. NORMAL CHARGING
[W2C1].
쐌 Never use more than 10 amperes when charging the
battery because that will shorten battery life.
3. JUDGMENT OF BATTERY IN CHARGED

CONDITION
1) Specific gravity of electrolyte is held at a specific value
in a range from 1.250 to 1.290 for more than one hour.
2) Voltage per battery cell is held at a specific value in a
range from 2.5 to 2.8 volts for more than one hour.
4. CHECK HYDROMETER FOR STATE OF CHARGE

Hydrometer indicator State of charge Required action
Green dot Above 65% Load test
Dark dot Below 65% Charge battery
Replace battery.* (If
Clear dot Low electrolyte
cranking complaint)
*: Check electrical system before replacement.
3. Ignition Switch
1. IGNITION SWITCH
1) Remove screws, separate upper column cover and
lower column cover.
B6M0236
3) Disconnect ignition switch connector from body har-

ness.
4) Using a drift and hammer, hit the torn bolt head to
loosen and remove the ignition switch.
B6M0333
5) When installing, tighten the connecting bolt until its

head twists off.
B6M0334A
7
3. Ignition Switch - 4. Headlight
B: INSPECTION
1. IGNITION SWITCH (ON-CAR)
2) Remove lower column cover.
3) Unfasten holddown clip which secures harness, and
disconnect connector of ignition switch from body harness.
4) Turn ignition key to each position and check continuity
between terminals of ignition switch connector.
Terminal
B6M0048 a-1 a-2 a-5 a-4
Position
LOCK
ACC 쎻 쎻
ON 쎻 쎻 쎻
START 쎻 쎻 쎻
4. Headlight
A: ADJUSTMENT
1. HEADLIGHT AIMING
1) Adjust the headlight aiming by turning the adjusting
screws.
CAUTION:
Before checking the headlight aiming, be sure of the
following:
B6M0335A 쐌 Turn off the light before adjusting headlight aiming.
If the light is necessary to check aiming, do not turn on
for more than two minutes.
쐌 The area around the headlight has not sustained any
accident, damage or other type of deformation.
쐌 Vehicle is parked on level ground.
쐌 The inflation pressure of tires is correct.
쐌 Vehicle’s gas tank is fully charged.
쐌 Bounce the vehicle several times to normalize the
suspension.
쐌 Make certain that someone is seated in the driver’s
seat.
NOTE:
Adjust vertical aim first, then horizontal aim.
8
3. Ignition Switch - 4. Headlight
B: INSPECTION
1. IGNITION SWITCH (ON-CAR)
disconnect connector of ignition switch from body harness.
4) Turn ignition key to each position and check continuity
between terminals of ignition switch connector.
Terminal
B6M0048 a-1 a-2 a-5 a-4
Position
LOCK
ACC 쎻 쎻
ON 쎻 쎻 쎻
START 쎻 쎻 쎻
4. Headlight
A: ADJUSTMENT
1. HEADLIGHT AIMING
1) Adjust the headlight aiming by turning the adjusting
screws.
CAUTION:
Before checking the headlight aiming, be sure of the
following:
B6M0335A 쐌 Turn off the light before adjusting headlight aiming.
If the light is necessary to check aiming, do not turn on
for more than two minutes.
쐌 The area around the headlight has not sustained any
accident, damage or other type of deformation.
쐌 Vehicle is parked on level ground.
쐌 The inflation pressure of tires is correct.
쐌 Vehicle’s gas tank is fully charged.
쐌 Bounce the vehicle several times to normalize the
suspension.
쐌 Make certain that someone is seated in the driver’s
seat.
NOTE:
Adjust vertical aim first, then horizontal aim.
8
4. Headlight
2) Look at the beam angle gauge (vertical movement).

The bubble on the gauge should not deviate from the cen-
ter of the gauge.
B6M0336A
3) Look at the beam angle gauge (horizontal movement).

The center mark (the red line on the inner scale) should not
deviate from the black line on the outer case.
B6M0337A
B: REMOVAL AND INSTALLATION

1. HEADLIGHT BULB
1) Disconnect the connector from inside of the engine
compartment.
2) Remove rubber cap.
3) Remove the light bulb retaining spring to remove the
bulb.
4) Replace the bulb with a new one and hook the spring.
5) Attach the rubber cap and connect the connector.
CAUTION:
쐌 Since the tungsten halogen bulb operates at high
temperature, dirt and oil on the bulb surface decreases
the bulb’s useful life. When replacing the bulb, hold the
flange portion and do not touch the glass portion.
M6A0139
쐌 Attach the rubber cap with letters TOP on the top so

that the drain hole will be on the lower side.
쐌 To keep water out, correctly engage the groove por-
tion of the rubber cap.
M6A0140
9
4. Headlight
2. HEADLIGHT
1) Remove front grille and disconnect connectors from
headlight.
2) Remove bolts which secure headlight and remove

headlight.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
NOTE:
When installing the headlight, securely fit clip into locating.
B6M0338
B6M0339
3. COMBINATION SWITCH (WITHOUT AIRBAG

MODEL)
Refer to 5-5 [W7A0] as for removal of combination
switch on airbag equipped model.
1) Remove steering wheel. <Ref. to 4-3 [W2A0].>
2) Remove screws which secure upper column cover to
lower column cover.
3) Remove screws which secure knee protector and
remove knee protector.
B6M0236
CAUTION:
When installing knee protector, ensure that harness is
not caught by adjacent parts.
4) Disconnect connector from body harness and undo
holddown band.
10
4. Headlight
5) Remove screws which secure switch and remove

switch.
CAUTION:
During installation (with key interlock)
쐌 When routing combination switch harness around
steering system, do not place it over key interlock
release knob.
쐌 After installing lower column cover, ensure that key
interlock release knob is accessible.
G6M0107
C: DISASSEMBLY AND ASSEMBLY

1. COMBINATION SWITCH
1) Remove screws which secure slip ring to combination
switch, and remove slip ring.
B6M0237
2) Remove screws which secure lighting switch, wiper and

washer switch. Remove both switches.
Assembly is in the reverse order of disassembly.
G6M0109
D: INSPECTION
1. COMBINATION SWITCH (ON-CAR)
11
4. Headlight

disconnect connectors from body harness.
4) Move combination switch to respective positions and
check continuity between terminals as indicated in the fol-
lowing tables:
Lighting switch
Terminal
c-1 c-2 c-3
Switch position
OFF
Tail 쎻 쎻
* 쎻 쎻
Head 쎻 쎻 쎻
Parking switch
Terminal
c-10 c-11 c-9
Switch position
OFF 쎻 쎻
* X X
B6M0238 ON 쎻 쎻
Dimmer and passing switch
Terminal
a-3 a-2 a-1 a-4
Switch position
Flash 쎻 쎻 쎻
* 쎻 쎻 쎻
Low beam 쎻 쎻
* 쎻 쎻 쎻
HI-beam 쎻 쎻
2. HEADLIGHT RELAY
Check continuity between terminals as indicated in table
below, when connecting the battery to terminal No. 1 and
No. 3.
Between terminals
When current flows. Continuity exists.
No. 2 and No. 4
Between terminals Continuity does not
No. 2 and No. 4 exist.
When current does not flow.
Between terminals
Continuity exists.
No. 1 and No. 3
G6M0111
12
4. Headlight
3. DAYTIME RUNNING LIGHT RELAY

Check continuity between terminals (indicated in table
below) when terminal No. 1 is connected to battery and
terminal No. 2 is grounded.
Between terminals
No. 3 and No. 4
Between terminals
Continuity exists.
No. 1 and No. 2
G6M0113
Check continuity between terminals (indicated in table

below) when terminal No. 1 is connected to battery and
terminal No. 2 is grounded.
When current flows.
Between terminals
Continuity exists.
No. 3 and No. 4
Between terminals
Continuity exists.
No. 3 and No. 5
Between terminals
Continuity exists.
No. 1 and No. 2
G6M0114
13
5. Stop and Tail Light

1. REAR COMBINATION LIGHT
1) Remove rear trim.
2) Disconnect connector from rear combination light.
3) Remove nuts which secure rear combination light.
Tightening torque:
2.5±0.5 N⋅m (0.25±0.05 kg-m, 1.8±0.4 ft-lb)
B6M0055A
4) Attach adhesive cloth tape to body area around rear
combination light.
5) Using a standard screwdriver, carefully pry rear combi-
nation light off and away from the vehicle.
CAUTION:
쐌 Do not pry rear combination light forcefully as this
may scratch vehicle body.
쐌 Remove all traces of adhesive tape from body before
installation.
쐌 Attach butyl rubber tape to back of rear combination
B6M0056A
light before installing rear combination light on body
for sealing purposes.
2. REAR FINISHER
1) Remove trunk lid trim (SEDAN) or rear gate trim
(WAGON).
2) Disconnect connectors from rear finisher.
3) Remove rear wiper motor (WAGON).
4) Remove nuts which secure rear finisher.
Tightening torque:
2.5±0.5 N⋅m (0.25±0.05 kg-m, 1.8±0.4 ft-lb)
5) Attach adhesive cloth tape to body area around rear
B6M0057A
finisher.
6) Using a standard screwdriver, carefully pry rear finisher
off and away from the vehicle.
CAUTION:
Do not pry rear finisher forcefully as this may scratch
vehicle body.
B6M0058A
14
3. HIGH-MOUNT STOP LIGHT (SEDAN)

1) Disconnect connector of high-mount stop light from
body harness.
2) Remove screws which secure high-mount stop light to
rear shelf panel.
3) Remove high-mount stop light.
B6M0340A
4. HIGH-MOUNT STOP LIGHT (WAGON)

1) Remove high-mount stop light cover from rear gate trim
panel.
2) Remove screws which secure high-mount stop light.
3) Remove high-mount stop light while disconnecting con-
nector from body harness.
B6M0341A
5. STOP LIGHT SWITCH

Refer to 4-5 [C101 (MT) or C201 (AT)] as for removal and
installation of stop light switch.
NOTE:
When installing the stop light switch, adjust the pedal
height by adjusting the stop light switch position.
Refer to 6-2 [W4B3] as for removal and installation of com-
bination switch.
B: DISASSEMBLY AND ASSEMBLY

Refer to 6-2 [W4C1] as for disassembly and assembly of
combination switch.
15
C: INSPECTION
1. STOP LIGHT SWITCH (ON-CAR)
Without cruise control model
1) Disconnect connector of stop light switch from body
harness.
2) Check continuity between terminals when push rod is
pushed in 4.0 to 4.5 mm (0.157 to 0.177 in) from end of
outer case.
B6M0059A Terminal
1 2
Switch position
When push rod is
pushed in.
When push rod is
쎻 쎻
released.
With cruise control model

harness.
outer case.
Terminal
1 2 3 4
Switch position
When push rod is
B6M0060A 쎻 쎻
pushed in.
When push rod is
쎻 쎻
released.
16
With TCS model

harness.
outer case.
Terminal
1 2 3 4
Switch position
When push rod is
B6M0342 쎻 쎻
pushed in.
When push rod is
쎻 쎻
released.

Refer to 6-2 [W4D1] as for inspection of combination
switch.
3. TAIL AND ILLUMINATION RELAY

below, when connecting battery to terminal No. 1 and No. 3
Between terminals
No. 2 and No. 4
Between terminals
Continuity exists.
No. 1 and No. 3
G6M0112
17
6. Turn Signal and Hazard Warning Light
6. Turn Signal and Hazard Warning

Light
1. FRONT TURN SIGNAL LIGHT
Refer to 6-2 [W4B2] as for removal and installation of front
turn signal light.
NOTE:
The front turn signal light is united with headlight assem-
bly.
2. REAR COMBINATION LIGHT
Refer to 6-2 [W5A1] as for removal and installation of rear
combination light.
bination switch.
4. HAZARD SWITCH
1) Remove center panel from instrument panel. <Ref. to
5-4 [W1A0].>
2) Disconnect connector of hazard switch from body har-
ness.
3) Remove hazard switch from center panel.
B6M0063
5. TURN SIGNAL AND HAZARD UNIT

2) Remove engine hood opener lever bracket.
3) Disconnect connector of turn signal and hazard unit.
4) Remove screw, and then remove turn signal and haz-
ard unit from bracket.
B6M0343A
18
6. Turn Signal and Hazard Warning Light
B: DISASSEMBLY AND ASSEMBLY

combination switch.
C: INSPECTION

4) Move combination switch to respective positions and
check continuity between terminals as indicated in table
below:
Turn signal switch
Terminal
a-5 a-7 a-6
Switch position
L⋅L′ 쎻 쎻
* x x
Turn N
* x x
R⋅R′ 쎻 쎻
B6M0238
2. HAZARD SWITCH
Move hazard switch to each position and check continuity
between terminals as indicated in table below:
7 3 9 10 5 6 1 2
ON 쎻 쎻 쎻 쎻 쎻 쎻 쎻
OFF 쎻 쎻 쎻 쎻
B6M0344
19
7. Back-up Light - 8. Room Light and Door Switch
7. Back-up Light
1. BACK-UP LIGHT
finisher.
2. BACK-UP LIGHT SWITCH (MT MODEL)

Refer to 3-1 [W2B1 (AWD) or W3A0 (FWD)] as for removal
and installation of back-up light switch.
3. INHIBITOR SWITCH (AT MODEL)

Refer to 3-2 [W4A4] as for removal and installation of
inhibitor switch (R position switch).
B: INSPECTION
Refer to 3-2 [W2B2] as for inspection of inhibitor switch.
8. Room Light and Door Switch

1. ROOM LIGHT
1) Pry room light lens off using a screwdriver.
2) Remove screws which secure room light body.
3) Remove room light body while disconnecting connector.
B6M0068
2. TRUNK ROOM LIGHT (SEDAN)

1) Turn trunk room light body by hand and remove it from
rear shelf panel.
2) Disconnect connector of trunk room light.
B6M0345A
3. LUGGAGE ROOM LIGHT (WAGON)

1) Pry luggage room light lens off using a screwdriver.
2) Remove screws which secure luggage room light body.
3) Remove luggage room light body while disconnecting
connector.
B6M0069
20
7. Back-up Light - 8. Room Light and Door Switch
7. Back-up Light
1. BACK-UP LIGHT
finisher.
2. BACK-UP LIGHT SWITCH (MT MODEL)

Refer to 3-1 [W2B1 (AWD) or W3A0 (FWD)] as for removal
and installation of back-up light switch.

inhibitor switch (R position switch).
B: INSPECTION
Refer to 3-2 [W2B2] as for inspection of inhibitor switch.

1. ROOM LIGHT
1) Pry room light lens off using a screwdriver.
2) Remove screws which secure room light body.
3) Remove room light body while disconnecting connector.
B6M0068
2. TRUNK ROOM LIGHT (SEDAN)

1) Turn trunk room light body by hand and remove it from
rear shelf panel.
2) Disconnect connector of trunk room light.
B6M0345A
3. LUGGAGE ROOM LIGHT (WAGON)

1) Pry luggage room light lens off using a screwdriver.
2) Remove screws which secure luggage room light body.
3) Remove luggage room light body while disconnecting
connector.
B6M0069
20
4. DOOR SWITCH
1) Remove rubber boot of door switch.
2) Remove screw which secures door switch to body.
3) Remove door switch while disconnecting connector.
B6M0070A
5. TRUNK ROOM LIGHT SWITCH (SEDAN)

Refer to 5-1 [W2A3] as for removal and installation of trunk
room light switch which is installed in trunk lid lock.
6. LUGGAGE ROOM LIGHT SWITCH (WAGON)

Refer to 5-2 [W3A2] as for removal and installation of lug-
gage room light switch which is installed in rear gate lock.
B: INSPECTION
1. DOOR SWITCH
Move switch and check continuity between terminal of door
switch and switch body.
Switch position Terminal Switch body
Open (ON) 쎻 쎻
Push in (OFF)
B6M0071
2. TRUNK ROOM LIGHT SWITCH (SEDAN)

Move switch and check continuity between terminals of
trunk room light switch.
Terminal
1 2
Switch position
Open (ON) 쎻 쎻
Push in (OFF)
B6M0072A
3. LUGGAGE ROOM LIGHT SWITCH (WAGON)

Move switch and check continuity between terminals of
luggage room light switch.
Terminal
1 2
Switch position
Open (ON) 쎻 쎻
Push in (OFF)
B6M0073A
21
9. Spot Light - 10. Front Wiper and Washer
9. Spot Light
1. SPOT LIGHT AND SWITCH
1) Pry spot light lens off using a screwdriver.
2) Remove screws which secure spot light body.
3) Remove spot light body while disconnecting connec-
tor(s).
B6M0346
B: INSPECTION
1. SPOT LIGHT SWITCH
Move switch and check continuity between terminal of spot
light switch connector and steel plate as shown.
Switch position Connector terminal Plate
Open (OFF)
Push in (ON) 쎻 쎻
B6M0347
10. Front Wiper and Washer

A: ON-CAR SERVICES
1. ADJUSTMENT
1) Turn the wiper switch to OFF position.
2) Adjust blades in original position as shown in figure by
changing wiper arm installation.
Original position:
A: 25 — 30 mm (0.98 — 1.18 in)
B: 35 — 40 mm (1.38 — 1.57 in)
G6M0115
3) Stop the vehicle.

4) Adjust washer ejecting point on windshield glass as
shown in figure.
Ejecting point:
A: 375 mm (14.76 in)
B: 150 mm (5.91 in)
C: 380 mm (14.96 in)
G6M0116
22
9. Spot Light - 10. Front Wiper and Washer
9. Spot Light
1. SPOT LIGHT AND SWITCH
tor(s).
B6M0346
B: INSPECTION
1. SPOT LIGHT SWITCH
Move switch and check continuity between terminal of spot
light switch connector and steel plate as shown.
Switch position Connector terminal Plate
Open (OFF)
Push in (ON) 쎻 쎻
B6M0347

A: ON-CAR SERVICES
1. ADJUSTMENT
1) Turn the wiper switch to OFF position.
2) Adjust blades in original position as shown in figure by
changing wiper arm installation.
Original position:
A: 25 — 30 mm (0.98 — 1.18 in)
B: 35 — 40 mm (1.38 — 1.57 in)
G6M0115
3) Stop the vehicle.

4) Adjust washer ejecting point on windshield glass as
shown in figure.
Ejecting point:
A: 375 mm (14.76 in)
B: 150 mm (5.91 in)
C: 380 mm (14.96 in)
G6M0116
22

1. BLADE
Pull out blade following the arrow direction from arm while
pushing up locking clip.
B6M0107A
2. WIPER ARM
1) Open engine hood.
2) Remove cap of wiper arm installation nut.
3) Remove the nut which secures wiper arm.
4) Remove wiper arm.
NOTE:
Remove metal sludge from the wiper arm fixture before
installing it.
G6M0118
Tightening torque:
20±3 N⋅m (2.0±0.3 kg-m, 14.5±2.2 ft-lb)
3. WIPER MOTOR AND LINK

1) Detach weatherstrip and cowl panel. <Ref. to 5-1
[W10A0].>
NOTE:
Apply silicone oil or soap water to both sides of cowl net to
facilitate removal.
2) Disconnect connector of wiper motor.

3) Remove motor attaching bolts.
Tightening torque:
5.9±1.5 N⋅m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
B6M0108
23
4) Remove wiper link from back side of wiper motor using

a screwdriver inserted into service hole in front panel.
CAUTION:
Do not pry wiper link off forcefully as this may scratch
vehicle body.
5) Remove wiper motor.
6) Separate the driver’s side wiper link from back side of
the passenger’s side wiper sleeve unit.
7) Remove nuts which secure sleeve unit.

Tightening torque:
5.9±1.5 N⋅m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
G6M0021
8) Remove wiper link from service hole in front panel.
G6M0121
4. WASHER TANK AND WASHER MOTOR

1) Remove washer tank attaching bolts.
2) Disconnect connectors of washer motors.
3) Disconnect washer hoses from each washer motor.
4) Remove washer tank and washer motor as an unit.
5) Separate washer motor from washer tank.
B6M0109A
5. NOZZLE
1) Disconnect washer hose from nozzle.
2) Push nozzle clip in direction A as shown in figure.
3) Remove nozzle from engine hood.
CAUTION:
Do not pry nozzle off forcefully as this may scratch
vehicle body.
B6M0110A
24
bination switch.

1. COMBINATION SWITCH AND INTERMITTENT UNIT
combination switch.
D: INSPECTION
25

4) Set wiper switch to each position and check continuity
Wiper switch
Terminal
d-9 d-8 d-6 d-7 INT1 INT2
Switch position
OFF 쎻 쎻
OFF * x x
MIST 쎻 쎻
OFF 쎻 쎻 쎻 쎻
INT * x x
MIST 쎻 쎻 쎻 쎻
* x x
OFF 쎻 쎻
LO
MIST 쎻 쎻
OFF 쎻 쎻
B6M0238
HI
MIST 쎻 쎻 쎻
Washer switch
Terminal
d-5 d-2
Switch position
OFF
ON 쎻 쎻
2. WIPER MOTOR
1) Check wiper motor operation at low speed.
Connect battery to wiper motor. Check wiper motor for
proper operation at low speed.
B6M0163
2) Check wiper motor operation at high speed.

Connect battery to wiper motor. Check wiper motor for
proper operation at high speed.
B6M0164
26
11. Rear Wiper and Washer
3) Check wiper motor for proper stoppage.

Connect battery to wiper motor. After operating wiper motor
at low speed, disconnect battery to stop it.
B6M0165
4) Reconnect battery and ensure that wiper motor stops at

“AUTO STOP” after operating at low speed.
B6M0166
3. WASHER MOTOR
Apply battery voltage between terminals of washer motor
connector and check that washer motor operates.
B6M0111

A: ON-CAR SERVICES
1. ADJUSTMENT
1) Adjust wiper blade in original position as shown in fig-
ure by changing wiper arm installation.
Original position:
A: 25 — 35 mm (0.98 — 1.38 in)
G6M0126
2) Adjust washer ejecting point on rear gate window as

shown in figure when the vehicle stops.
Ejecting point:
A: 25 mm (0.98 in)
B: 200 — 300 mm (7.87 — 11.81 in)
G6M0127
27

Connect battery to wiper motor. After operating wiper motor
at low speed, disconnect battery to stop it.
B6M0165

“AUTO STOP” after operating at low speed.
B6M0166
3. WASHER MOTOR
B6M0111

A: ON-CAR SERVICES
1. ADJUSTMENT
1) Adjust wiper blade in original position as shown in fig-
ure by changing wiper arm installation.
Original position:
A: 25 — 35 mm (0.98 — 1.38 in)
G6M0126
2) Adjust washer ejecting point on rear gate window as

shown in figure when the vehicle stops.
Ejecting point:
A: 25 mm (0.98 in)
B: 200 — 300 mm (7.87 — 11.81 in)
G6M0127
27

1. BLADE
Pull out blade following the arrow direction, from arm while
pushing up locking clip.
B6M0107A
2. WIPER ARM
1) Remove head cover.
2) Remove nut and wiper arm.
Tightening torque:
5.9±1.5 N⋅m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
B6M0112
3. WIPER MOTOR
1) Remove cap and special nut.
CAUTION:
Be careful not to strike service tool against nozzle dur-
ing removal.
Tightening torque:
7.4±1.5 N⋅m (0.75±0.15 kg-m, 5.4±1.1 ft-lb)
B6M0113
2) Remove rear gate trim. <Ref. to 5-2 [W3A1].>

3) Undo clips which secure harness, and disconnect con-
nector of wiper motor.
4) Separate washer hoses at joint.

5) Remove attaching screws and take out wiper motor
assembly.
CAUTION:
Be careful not to damage O-ring when removing wiper
motor assembly.
Tightening torque:
5.9±1.5 N⋅m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
B6M0114
28
4. WASHER TANK AND WASHER MOTOR

Refer to 6-2 [W10B4] as for removal and installation of
washer tank and washer motor.
bination switch.

combination switch.
D: INSPECTION
29

4) Set rear wiper and washer switch to each position and
below:
Terminal
d-2 d-1 d-3
Switch position
WASH 쎻 쎻
OFF
ON 쎻 쎻
WASH 쎻 쎻 쎻
B6M0238
2. WIPER MOTOR
1) Operational check
Connect battery to wiper motor and check operation of
wiper motor.
B6M0167

After operating wiper motor, disconnect battery from wiper
motor.
B6M0168

“AUTO STOP” after it has been operated.
B6M0169
30
11. Rear Wiper and Washer - 12. Rear Window Defogger
3. REAR WIPER RELAY

1) Connect battery to terminal No. 1 and ground terminal
No. 2.
2) Check continuity between terminals as indicated in
table below:
When current flows. Between terminals Continuity does not
Between terminals Continuity exists.
No. 3 and No. 4
When current does not flow. Between terminals Continuity exists.
No. 3 and No. 5
No. 1 and No. 2
G6M0134
4. WASHER MOTOR
B6M0111
12. Rear Window Defogger

1. DEFOGGER SWITCH
1) Remove screws which secure meter visor.
2) Remove meter visor from instrument panel while dis-
connecting connectors.
3) Remove rear window defogger switch from meter visor.
B: INSPECTION
1. DEFOGGER SWITCH
Move rear window defogger switch to each position and
below:
Terminal
3 5 1 4 2
Switch position
OFF 쎻 쎻
ON 쎻 쎻 쎻 쎻 쎻
B6M0119
31
11. Rear Wiper and Washer - 12. Rear Window Defogger
3. REAR WIPER RELAY

No. 2.
table below:
No. 3 and No. 4
No. 3 and No. 5
No. 1 and No. 2
G6M0134
4. WASHER MOTOR
B6M0111

1. DEFOGGER SWITCH
3) Remove rear window defogger switch from meter visor.
B: INSPECTION
1. DEFOGGER SWITCH
Move rear window defogger switch to each position and
below:
Terminal
3 5 1 4 2
Switch position
OFF 쎻 쎻
ON 쎻 쎻 쎻 쎻 쎻
B6M0119
31
2. DEFOGGER RELAY
No. 3.
Between terminals
No. 2 and No. 4
Between terminals
Continuity exists.
No. 1 and No. 3
G6M0112
3. HEAT WIRES
1) Start the engine so that battery is being charged.
2) Turn defogger switch to ON.
3) Check each heat wire at its center position for discon-
tinuity by setting direct current voltmeter.
Normal indication is about 6 volts.
G6M0135
NOTE:
When measuring voltage, wind a piece of tin foil around the
tip of the tester probe and press the foil against the wire
with your finger.
G6M0136
32
12. Rear Window Defogger - 13. Combination Meter
4) When tester indicates 12 volts when its probe reaches

point “A”, a broken circuit occurs between point “A” and the
negative terminal. Slowly move tester probe toward the
negative terminal while contacting it on heat wire to locate
point where tester indication changes abruptly (0 volts).
This is the point where a broken circuit occurs.
When tester indicates 0 volts when its probe reaches point
“A”, a broken circuit occurs between point “A” and the posi-
tive terminal. Locate a point where tester indication
changes abruptly (12 volts) while slowly moving tester
probe toward the positive terminal.
G6M0137
C: REPAIR
1) Clean broken wire and its surrounding area.
2) Cut off slit on (used) thin film by 0.5 mm (0.020 in) width
and 10 mm (0.39 in) length.
3) Place the slit on glass along the broken wire, and
deposit conductive silver composition (DUPONT No. 4817)
on the broken portion.
4) Dry out the deposited portion.
5) Inspect the repaired wire for continuity.
G6M0138
13. Combination Meter

1. COMBINATION METER
1) Move steering wheel fully down.
3) Remove visor from instrument panel.
4) Disconnect connectors from meter visor.
B6M0120
5) Remove screws which secure combination meter, and

pull combination meter out.
6) Disconnect connectors from back of combination meter.
CAUTION:
When installing combination meter, be sure to connect
connectors to backside of combination meter.
B6M0121
33
12. Rear Window Defogger - 13. Combination Meter
4) When tester indicates 12 volts when its probe reaches

point “A”, a broken circuit occurs between point “A” and the
negative terminal. Slowly move tester probe toward the
negative terminal while contacting it on heat wire to locate
point where tester indication changes abruptly (0 volts).
This is the point where a broken circuit occurs.
When tester indicates 0 volts when its probe reaches point
“A”, a broken circuit occurs between point “A” and the posi-
tive terminal. Locate a point where tester indication
changes abruptly (12 volts) while slowly moving tester
probe toward the positive terminal.
G6M0137
C: REPAIR
1) Clean broken wire and its surrounding area.
2) Cut off slit on (used) thin film by 0.5 mm (0.020 in) width
and 10 mm (0.39 in) length.
3) Place the slit on glass along the broken wire, and
deposit conductive silver composition (DUPONT No. 4817)
on the broken portion.
4) Dry out the deposited portion.
5) Inspect the repaired wire for continuity.
G6M0138

1. COMBINATION METER
1) Move steering wheel fully down.
3) Remove visor from instrument panel.
4) Disconnect connectors from meter visor.
B6M0120
5) Remove screws which secure combination meter, and

pull combination meter out.
6) Disconnect connectors from back of combination meter.
CAUTION:
When installing combination meter, be sure to connect
connectors to backside of combination meter.
B6M0121
33
B: BULB REPLACEMENT
B6M0348A
쎻
1 Tachometer and temperature 쎻
7 Door open 쎻
13 Low fuel
gauge illumination 쎻
8 Seat belt 쎻
14 Charge
쎻
2 Oil pressure 쎻
9 TCS (Operation indicator) 쎻
15 Brake fluid level/parking brake
쎻
3 CHECK ENGINE (Malfunction Indi- 쎻
10 Turn signal (LH) 쎻
16 FWD
cator Light) 쎻
11 Speedometer illumination 쎻
17 AT oil temperature
쎻
4 Tachometer illumination 쎻
12 Speedometer and fuel gauge illumi- 쎻
18 ABS
쎻
5 Turn signal (RH) nation 쎻
19 TCS (Warning)
쎻
6 Headlight beam
34
14. Vehicle Speed Sensor 2

A: GENERAL PRECAUTIONS
1) Be careful not to drop or bump sensor as this may break
built-in magnet.
2) Drive key is designed to separate from vehicle speed
sensor 2. Be careful not to lose it or forget to install.
3) Vehicle speed sensor 2 is installed in part (which con-
tains bearings, etc., finished to a high degree of accuracy).
Do not allow foreign matter (filings, sand, etc.) to get into
it.
4) When checking output of vehicle speed sensor 2 as a
single unit, ensure test leads are connected to their correct
terminals. Failure to do this may damage internal IC.
5) Discard vehicle speed sensor 2 after removal; replace
with new one.
B: REMOVAL
CAUTION:
쐌 Be careful when removing vehicle speed sensor 2
immediately after driving vehicle for a while, as tem-
perature around it is high.
쐌 Before removing vehicle speed sensor 2, clean dirt,
etc. from surrounding areas. Take care not to allow
foreign matter to get into mounting hole.
1) Remove collector cover.

2) Disconnect vehicle speed sensor 2 connector.
3) Turn and remove vehicle speed sensor 2.
4) Remove key and packing.
B2M0211
35
C: INSTALLATION
CAUTION:
쐌 Ensure sensor mounting hole is clean and free of
foreign matter.
쐌 Apply grease to tip end of key to prevent key from
falling off sensor.
쐌 Align tip end of key with key groove on end of
speedometer shaft during installation.
1) Hand tighten vehicle speed sensor 2, then tighten it
using suitable tool.
Tightening torque required for sensor to reach bottom of
transmission is as follows:
Tightening torque:
0.39 — 0.88 N⋅m (4.0 — 9.0 kg-cm, 3.5 — 7.8 in-lb)
CAUTION:
쐌 When torque must be applied that exceeds 0.88 N⋅m
(9.0 kg-cm, 7.8 in-lb), the key and key groove on end of
speedometer may not be aligned properly. Remove the
key, align it correctly and reassemble.
쐌 Sensor threads are secured by Locktite. The reas-
sembly must be completed within 5 minutes before
Locktite dries.
2) Tighten vehicle speed sensor 2 further to specified
torque.
Tightening torque:
5.9±1.5 N⋅m (60±15 kg-cm, 52±13 in-lb)
36
15. Horn and Cigarette Lighter
15. Horn and Cigarette Lighter

1. HORN
1) Open the engine hood.
2) Disconnect connector of horn.
3) Remove the horn.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B6M0349
CAUTION:
After installing horn, connect connector, fit firmly wir-
ing harness to prevent from disconnecting due to
vibration.
2. HORN SWITCH (HORN PAD)

1) Remove screw which secures horn switch (steering
pad) to the base of steering wheel.
2) Remove horn switch (steering pad) from steering wheel
while disconnecting connector.
B6M0124
3. CIGARETTE LIGHTER
1) Remove center panel from instrument panel. <Ref. to
5-4 [W1A0].>
2) Disconnect connector from cigarette lighter.
3) Turn illumination socket 45° counterclockwise and
remove it.
4) Loosen nut, and then remove cigarette lighter body.
CAUTION:
쐌 Align socket with cutout portion of instrument panel
B6M0350A during installation.
쐌 In case of replacing cigarette lighter, use genuine
part only and always replace both plug and socket
combination.
37
16. Power Window
B: INSPECTION
1. HORN SWITCH
Ensure that horn switch is free from the following defects:
1) Burned or shorted contacts
2) Broken or weak spring
3) Damaged harness
4) Worn or corroded mating surface of horn plate
2. HORN RELAY
below, when connecting the battery to terminals No. 1 and
No. 2.
When current flows. Between terminals Continuity exists.
No. 2 and No. 3
When current does not flow. Between terminals Continuity does not
No. 1 and No. 2
B6M0126A
3. HORN
Make sure that horn sounds when battery voltage is
applied between connector terminal and horn body.
B6M0127
1) Remove plug. Then, check element’s contact for wear,
and element for accumulation of ashes, foreign particles,
etc.
2) Check element for discontinuity.
3) Remove socket and clean element. Then, check for
wear or foreign particles on element’s contact and mating
surface.
4) Ensure that cigarette lighter returns within 20 seconds
after it is turned to ON.
16. Power Window

1. MAIN SWITCH, SUB SWITCH AND POWER
WINDOW MOTOR
power window main switch, sub switch and motor.
NOTE:
To remove the power window motor, it is necessary to dis-
assemble the door component parts.
38
16. Power Window
B: INSPECTION
1. HORN SWITCH
Ensure that horn switch is free from the following defects:
1) Burned or shorted contacts
2) Broken or weak spring
3) Damaged harness
4) Worn or corroded mating surface of horn plate
2. HORN RELAY
below, when connecting the battery to terminals No. 1 and
No. 2.
No. 2 and No. 3
No. 1 and No. 2
B6M0126A
3. HORN
Make sure that horn sounds when battery voltage is
applied between connector terminal and horn body.
B6M0127
1) Remove plug. Then, check element’s contact for wear,
and element for accumulation of ashes, foreign particles,
etc.
2) Check element for discontinuity.
3) Remove socket and clean element. Then, check for
wear or foreign particles on element’s contact and mating
surface.
4) Ensure that cigarette lighter returns within 20 seconds
after it is turned to ON.
16. Power Window

1. MAIN SWITCH, SUB SWITCH AND POWER
WINDOW MOTOR
power window main switch, sub switch and motor.
NOTE:
To remove the power window motor, it is necessary to dis-
38
16. Power Window
B: INSPECTION
1. MAIN SWITCH
Set power window main switch to each position and check
continuity between terminals as indicated in table below:
B6M0128A
LHD model
Switch Front RH Front LH Rear RH Rear LH
Window lock switch
Position 7 14 9 12 7 13 8 12 7 6 11 12 7 10 5 12
UP 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻
OFF 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻
NORMAL
쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻
DOWN
UP 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻
OFF 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻
LOCK
쎻 쎻
DOWN 쎻 쎻 쎻 쎻 쎻 쎻
쎻 쎻
RHD model
Switch Front RH Front LH Rear RH Rear LH
Window lock switch
Position 7 11 6 12 7 10 5 12 7 9 14 12 7 13 8 12
AUTO UP 쎻 쎻 쎻 쎻
UP 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻
OFF 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻 쎻
DOWN
쎻 쎻
AUTO DOWN
쎻 쎻
39
16. Power Window
2. SUB SWITCH
Set power window sub switch to each position and check
Terminal 5 1 3 4 2
Switch position
쎻 쎻
UP
쎻 쎻
쎻 쎻
OFF
쎻 쎻
쎻 쎻
DOWN
쎻 쎻
B6M0129A
3. POWER WINDOW MOTOR

1) Make sure that power window motor rotates properly
when battery voltage is applied to terminals of motor con-
nector.
2) Change polarity of battery connections to terminals to
ensure that motor rotates in reverse direction.
4. POWER WINDOW RELAY

No. 3.
No. 2 and No. 4
No. 1 and No. 3
B6M0130A
40
17. Power Door Lock
17. Power Door Lock

1. FRONT AND REAR DOOR, AND REAR GATE LOCK
ACTUATOR
Refer to 5-2 [W2A7] as for removal and installation of front
door lock actuator, rear door lock actuators, and rear gate
lock actuator.
NOTE:
To remove and install the actuators, it is necessary to dis-
2. DOOR LOCK TIMER

1) Remove glove box.
2) Remove back pocket cover.
3) Remove two bolts located at the rear of back pocket
cover.
4) Remove instrument panel side right cover and bolt.
5) Remove clip located at the inside end of instrument
panel.
6) Remove nut which secures door lock timer, and remove
B6M0351A door lock timer from bracket while pulling right side lower
end of instrument panel.
CAUTION:
Be careful not to damage instrument panel while pull-
ing its right side lower end.
7) Disconnect connector from door lock timer.
41
17. Power Door Lock - 18. Remote Controlled Rearview Mirror
B: INSPECTION
1. DOOR LOCK SWITCH (DRIVER’S DOOR)
1) Remove door trim panel. <Ref. to 5-2 [W2A2].>
2) Disconnect connector of door switch.
3) Set switch to each position and check continuity
Terminal
1 2
Switch position
B6M0133 UNLOCK 쎻 쎻
LOCK
2. ACTUATOR
2) Disconnect connector of actuator.
3) Make sure that door link moves to LOCK or UNLOCK
position when battery voltage is applied between terminals
as described below:
쐌 Connect battery positive (+) terminal to terminal No. 2,
and negative (−) terminal to terminal No. 4 at a moment.
B6M0135 and negative terminal (−) to terminal No. 2 at a moment.
18. Remote Controlled Rearview Mirror

1. REMOTE CONTROLLED REARVIEW MIRROR
SWITCH
1) Remove rearview mirror switch from instrument panel
by using a small standard screwdriver.
CAUTION:
Do not pry rearview mirror switch forcefully as this
B6M0352A may scratch instrument panel.
2) Remove rearview mirror switch while disconnecting
connector.
42
17. Power Door Lock - 18. Remote Controlled Rearview Mirror
B: INSPECTION
1. DOOR LOCK SWITCH (DRIVER’S DOOR)
2) Disconnect connector of door switch.
Terminal
1 2
Switch position
B6M0133 UNLOCK 쎻 쎻
LOCK
2. ACTUATOR
2) Disconnect connector of actuator.
3) Make sure that door link moves to LOCK or UNLOCK
position when battery voltage is applied between terminals
as described below:
and negative (−) terminal to terminal No. 4 at a moment.
B6M0135 and negative terminal (−) to terminal No. 2 at a moment.

1. REMOTE CONTROLLED REARVIEW MIRROR
SWITCH
1) Remove rearview mirror switch from instrument panel
by using a small standard screwdriver.
CAUTION:
Do not pry rearview mirror switch forcefully as this
B6M0352A may scratch instrument panel.
2) Remove rearview mirror switch while disconnecting
connector.
42
2. REARVIEW MIRROR
2) Disconnect connector of rearview mirror.
3) Remove screws which secure rearview mirror, and then
remove rearview mirror.
B6M0137
B: INSPECTION
1. REARVIEW MIRROR SWITCH
Move rearview mirror switch to each position and check
Switch Mirror switch Left/Right changing switch
position
Terminal OFF Right Left Up Down Left N Right
7 쎻
9 쎻
6 쎻
8 쎻
2 쎻 쎻 쎻 쎻
쎻 쎻 쎻 쎻
1 쎻 쎻 쎻 쎻
쎻 쎻 쎻 쎻
4 쎻 쎻 쎻 쎻
3
B6M0139A
2. REARVIEW MIRROR
Check to ensure that rearview mirror moves properly when
battery voltage is applied to terminals as indicated in table
below:
Terminal connection
Operation
(+) (−)
UP 3 1
DOWN 1 3
B6M0140 RIGHT 1 2
LEFT 2 1
43
19. Sunroof
19. Sunroof
1. SUNROOF AND SUNROOF MOTOR
sunroof system.
2. SUNROOF SWITCH
NOTE:
The sunroof switch is installed in spot light body.
tors.
4) Remove screw which secures sunroof switch, and then
remove sunroof switch.
B6M0353A
B: INSPECTION
1. SUNROOF SWITCH
Set sunroof switch to each position and check continuity
Terminal
4 3 6 5 2
Switch position
Open 쎻 쎻
Close 쎻 쎻
Tilt up 쎻 쎻
B6M0142A
Tilt down 쎻 쎻
2. SUNROOF MOTOR
1) Apply battery voltage between 1-pin connector and
body ground wire.
2) Make sure that sunroof motor moves when connecting
terminals as described below:
쐌 Connect between terminals No. 3 and 4 (OPEN)
쐌 Connect between terminals No. 6 and 4 (CLOSE)
쐌 Connect between terminals No. 5 and 4 (TILT UP)
쐌 Connect between terminals No. 2 and 4 (TILT DOWN)
B6M0503
44
19. Sunroof - 20. Radio, Speaker and Antenna
3. SUNROOF RELAY
below, when battery voltage is applied between terminals
No. 1 and No. 3.
No. 2 and No. 4
No. 1 and No. 3
B6M0144A
20. Radio, Speaker and Antenna

1. RADIO BODY
1) Remove hand brake cover.
2) Remove console cover.
3) Remove screws which secure center panel. Remove
center panel.
B6M0354
4) Remove fitting screws, and slightly pull radio out of

instrument panel.
5) Disconnect connectors and antenna feeder cord.
B6M0355
2. FRONT SPEAKER
1) Remove gusset speaker from behind the rearview mir-
ror while disconnecting connector.
B6M0146
45
19. Sunroof - 20. Radio, Speaker and Antenna
3. SUNROOF RELAY
below, when battery voltage is applied between terminals
No. 1 and No. 3.
No. 2 and No. 4
No. 1 and No. 3
B6M0144A

1. RADIO BODY
1) Remove hand brake cover.
2) Remove console cover.
3) Remove screws which secure center panel. Remove
center panel.
B6M0354
4) Remove fitting screws, and slightly pull radio out of

instrument panel.
5) Disconnect connectors and antenna feeder cord.
B6M0355
2. FRONT SPEAKER
1) Remove gusset speaker from behind the rearview mir-
ror while disconnecting connector.
B6M0146
45
3) Disconnect connector from speaker.

4) Remove screws which secure the speaker.
5) Remove door mount speaker.
B6M0162
3. REAR SPEAKER (SEDAN)

1) Remove rear seat cushion and rear backrest.
2) Remove left and right rear quarter trim panels.
3) Remove rear shelf trim panel.
4) Remove screws which secure speaker.
5) Remove speaker while disconnecting connector from
speaker.
4. REAR SPEAKER (WAGON)

2) Disconnect connector from speaker.
3) Remove screws which secure the speaker.
4) Remove speaker.
5. POWER ANTENNA
1) Remove left side trunk trim (SEDAN), or left side rear
lower quarter trim (WAGON).
2) Remove special nut (SEDAN).
3) Remove bolt which secures power antenna.
4) Remove power antenna while disconnecting connector
and water drain hose.
B6M0147A
B: INSPECTION
1. POWER ANTENNA
1) Connect battery positive (+) terminal to terminal No. 3
and connect terminal No. 1 (SEDAN) or No. 6 (WAGON)
to ground. Ensure that antenna rod extends properly when
battery positive (+) terminal is connected to terminal No. 2
(SEDAN) or No. 4 (WAGON).
2) Ensure that antenna rod retracts properly when battery
positive (+) terminal is disconnected from terminal No. 2
B6M0149A
(SEDAN) or No. 4 (WAGON).
46
21. Cruise Control
21. Cruise Control

A: ADJUSTMENT
B6M0356A
CAUTION: Tightening torque: N⋅m (kg-m, ft-lb)

쎻
A : Must be adjusted when cable end outer is fixed in place,
T: 6.4 — 11.3 (0.65 — 1.15, 4.7 — 8.3)
so that gap between throttle cam and lever is 1−10 mm
0
(0.04 −0.04 in).
(Must be attached while throttle cam is being pulled by wire
cable.)
쎻
B : Must be coated evenly on cam end inner connection.
쎻
C : Cover must be inserted securely, until tip of cable
touches cover stopper.
47
21. Cruise Control

1. CRUISE CONTROL MAIN SWITCH
3) Remove cruise control main switch from meter visor.
B6M0154A
2. CRUISE CONTROL COMMAND SWITCH

1) Remove screw which secures horn pad to the base of
steering wheel.
2) Remove horn pad from steering wheel while discon-
necting connector.
3) Disconnect connector of cruise control command
switch.
4) Remove screws which secure cruise control command
switch to steering wheel, and then remove command
B6M0357A switch.
WARNING:
Refer to 5-5 when removing or installing the module
from the airbag equipped model.
3. ACTUATOR
1) Loosen nut which secures cruise control cable end to
throttle cam, and then remove cable from engine throttle
cam.
2) Remove clip bands from cruise control cable.
CAUTION:
쐌 Be careful not to apply excessive load to the wire
cable when adjusting and/or installing; otherwise, the
actuator may be deformed or damaged.
B6M0156 쐌 Do not bend cable sharply with a radius less than
100 mm (3.94 in); otherwise, cable may bend
permanently, resulting in poor performance.
쐌 When installing cable, be careful not to sharply bend
or pinch the inner cable; otherwise, the cable may
break.
48
21. Cruise Control
3) Remove nuts which secure actuator.

4) Remove actuator while disconnecting vacuum hose.
Tightening torque:
7.4±1.5 N⋅m (0.75±0.15 kg-m, 5.4±1.1 ft-lb)
B6M0358
4. VACUUM PUMP AND VALVES

1) Disconnect connector from vacuum pump.
2) Remove bolts which secure vacuum pump.
3) Remove A/C receiver/drier bracket.
4) Remove vacuum pump while disconnecting vacuum
hose.
Tightening torque:
7.4±1.5 N⋅m (0.75±0.15 kg-m, 5.4±1.1 ft-lb)
B6M0359A
5. STOP AND BRAKE SWITCH

Refer to 4-5 [C101 (MT) or C201 (AT)] as for removal and
installation of stop and brake switch.
6. CLUTCH SWITCH (MT)
Refer to 4-5 [C101] as for removal and installation of clutch
switch.
7. INHIBITOR SWITCH (AT)
inhibitor switch.
8. CRUISE CONTROL MODULE

1) Follow the same preparatory procedures when remov-
ing door lock timer. <Ref. to 6-2 [W17A2].>
2) Remove nuts which secure cruise control module, and
remove cruise control module from bracket while pulling
right side lower end of instrument panel.
CAUTION:
B6M0360A
3) Disconnect connector from cruise control module.
4) Installation is the reverse order of removal.
49
21. Cruise Control
C: DRIVING TESTS
Conduct road tests by selecting a smooth, flat road or use
free rollers as road test simulation.
1. MAIN SWITCH
1) Turn ignition switch ON.
2) Check that indicator light comes on when main switch
is pressed (ON).
3) Check that indicator light goes out when main switch is
pressed again (OFF).
4) Turn ignition switch OFF with main switch ON (which is
indicated by illumination.).
5) Turn ignition switch ON again to ensure that indicator
light remains OFF.
2. COMMAND SWITCH
1) Check that command switch is properly set in “SET/
COAST”, “RESUME/ACCEL” or “CANCEL” mode.
2) Also check that command switch returns to the original
position when released.
3. CONSTANT SPEED TEST

1) Turn main switch ON.
2) Drive vehicle at speed greater than 40 km/h (25 MPH).
3) Press command switch to set in “SET/COAST” mode.
4) Ensure that vehicle is maintained at the speed set when
command switch was pressed.
4. ACCELERATION TEST
1) Set vehicle speed at speed greater than 40 km/h (25
MPH).
2) Ensure that vehicle continues to accelerate while hold-
ing command switch in RESUME/ACCEL mode, and that
vehicle maintains that optional speed when command
switch is released.
5. DECELERATION TEST
1) Set vehicle speed at optional speed greater than 40
km/h (25 MPH).
2) Ensure that vehicle continues to decelerate while hold-
ing command switch in SET/COAST mode, and that it
maintains that optional speed when command switch is
released.
NOTE:
When vehicle speed reaches the lower speed limit of 30
km/h (19 MPH) during deceleration, cruise control will be
released.
50
22. Security System
22. Security System

1. STARTER INTERRUPT RELAY
NOTE:
The starter interrupt relay and headlight alarm relay use the
same parts and are mounted parallel to each other.
Therefore, before removal and installation, identify the
starter interrupt relay by the color of its wiring connection.
B6M0361A <Ref. to 6-3 [WIRING DIAGRAM SECTION].>
2) Disconnect connector of starter interrupt relay.
3) Remove starter interrupt relay.
2. HEADLIGHT ALARM RELAY

NOTE:
The headlight alarm relay and starter interrupt relay use the
same parts and are mounted parallel to each other.
Therefore, before removal and installation, identify the
headlight alarm relay by the color of its wiring connection.
<Ref. to 6-3 [WIRING DIAGRAM SECTION].>
2) Disconnect connector of headlight alarm relay.
B6M0361A 3) Remove headlight alarm relay.
3. ENGINE HOOD SWITCH

1) Disconnect connector of engine hood switch from bot-
tom side of switch body.
2) Remove headlight (LH).
3) Remove attaching bolt, and then remove engine hood
switch.
B6M0363A
51
22. Security System
4. KEY CYLINDER LOCK/UNLOCK SWITCH AND

TAMPER SWITCH
NOTE:
The key cylinder lock switch, unlock switch and tamper
switch are united in the switch body.
Door Switch
1) Remove door trim panel and sealing cover. <Ref. to 5-2
[W2A3].>
2) Disconnect connector of door key cylinder switch from
B6M0364A
door cord.
3) Remove door outer handle. <Ref. to 5-2 [W2A8].>
CAUTION:
Be careful not to damage the door surface.
4) Remove clip, and then remove door key cylinder switch
from door outer handle.
Trunk Lid Switch (SEDAN)

1) Disconnect connector of trunk lid key cylinder switch.
2) Disconnect rod from key cylinder.
3) Remove trunk lid key cylinder switch by pushing it.
Rear Gate Switch (WAGON)

1) Disconnect connector of rear gate key cylinder switch.
2) Disconnect rod from key cylinder.
3) Remove attaching bolts, and then remove rear gate key
cylinder switch.
B6M0368A
5. DOOR LOCK/UNLOCK SWITCH

NOTE:
The door lock/unlock switch is united with the power door
lock actuator.
Driver and Passenger Door
1) Remove door trim panel and sealing cover. <Ref. to 5-2
[W2A3].>
2) Disconnect connector of door lock actuator assembly
from door code.
52
22. Security System
3) Remove door lock actuator assembly. <Ref. to 5-2

[W2A7].>
Rear Gate (WAGON)

1) Remove rear gate trim panel.
2) Disconnect rod from rear gate latch assembly.
3) Disconnect rear gate switch connector and power door
lock actuator connector.
4) Remove bolts which secure power door lock actuator.
5) Remove bolts which secure latch.
6) Remove latch and actuator assembly.
6. DOOR SWITCH
1) Remove rubber boot of door switch.
2) Remove screw which secures door switch to body.
3) Remove door switch while disconnecting connector.
B6M0070A
7. TRUNK LID SWITCH (SEDAN)

NOTE:
The trunk lid switch is united with the trunk lid lock.
1) Remove trunk rear trim.
2) Disconnect connector of trunk switch (combined with
trunk room light switch).
3) Put matching mark on the trunk lid lock and vehicle
body before removal.
4) Remove bolts, then remove trunk lid lock from vehicle
B6M0371A body.
NOTE:
Ensure that matching mark is aligned between trunk lid
lock and vehicle body.
53
22. Security System
8. REAR GATE SWITCH (WAGON)

NOTE:
The rear gate switch is united with the rear gate latch
assembly.
1) Remove rear gate trim panel.
2) Disconnect rod from rear gate latch assembly.
3) Disconnect rear gate switch (combined with luggage
room light switch) connector and power door lock actuator
connector.
B6M0372A 4) Remove bolts which secure power door lock actuator.
5) Remove bolts which secure latch.
6) Remove latch and actuator assembly.
9. SECURITY INDICATOR LIGHT

3) Remove security indicator light from meter visor.
B6M0373A
10. SECURITY CONTROL MODULE

1) Follow the same preparatory procedures when remov-
ing door lock timer. <Ref. to 6-2 [W17A2].>
2) Remove nut which secures security control module,
and remove security control module from bracket while
pulling right side lower end of instrument panel.
CAUTION:
B6M0682A
3) Disconnect connector from security control module.
54
22. Security System
B: INSPECTION
1. STARTER INTERRUPT RELAY
1) Disconnect connector of starter interrupt relay.
2) Connect battery to terminal No.1 and ground terminal
No. 2.
table below:
No. 3 and No. 5
No. 1 and No. 2
B6M0375A
2. HEADLIGHT ALARM RELAY

1) Disconnect connector of headlight alarm relay.
No. 2.
table below:
No. 3 and No. 4
No. 3 and No. 5
No. 1 and No. 2
G6M0134
3. ENGINE HOOD SWITCH

1) Disconnect connector of engine hood switch.
pushed in 1.5 mm (0.059 in) of its stroke.
Terminal
1 2
Switch position
When push rod is
pushed in.
When push rod is
쎻 쎻
B6M0376 released.
55
22. Security System
4. KEY CYLINDER LOCK/UNLOCK SWITCH AND

TAMPER SWITCH
Door Switch
1) Disconnect connector of door key cylinder switch.
2) Move switch by turning the key cylinder with ignition key
and/or remove switch from key cylinder to check continuity
Terminal
1 2 3 4
Switch position
B6M0377
Normal
LOCK 쎻 쎻
UNLOCK 쎻 쎻
Switch is removed from
쎻 쎻
key cylinder.
Trunk Lid Switch (SEDAN)

1) Disconnect connector of trunk lid key cylinder switch.
and/or remove switch from key cylinder to check continuity
Terminal
1 2 3
Switch position
Normal
B6M0378A UNLOCK 쎻 쎻
Switch is removed from
쎻 쎻
key cylinder.
56
22. Security System
Rear Gate Switch (WAGON)

1) Disconnect connector of rear gate key cylinder switch.
and check continuity between terminals as indicated in
table below:
Terminal
1 2 4
Switch position
Normal
B6M0379 LOCK 쎻 쎻
UNLOCK 쎻 쎻
5. DOOR LOCK/UNLOCK SWITCH

NOTE:
The door lock/unlock switch is united with the power door
lock actuator.
1) Disconnect connector of door lock/unlock switch.
Driver’s Door
Terminal
B6M0133A 1 2
Switch position
UNLOCK 쎻 쎻
LOCK
Passenger’s Door
Terminal
1 2 3 4
Switch position
UNLOCK 쎻 쎻
LOCK
Rear Gate (WAGON)
B6M0381A
Terminal
1 2 3 4
Switch position
UNLOCK 쎻 쎻
LOCK
57
22. Security System
6. DOOR SWITCH
Refer to 6-2 [W8B1] as for inspection of door switch.
NOTE:
The door switch is combined with the door switch for room
light.
7. TRUNK LID SWITCH (SEDAN)

Refer to 6-2 [W8B2] as for inspection of trunk lid switch.
NOTE:
The trunk lid switch is combined with the trunk room light
switch.
8. REAR GATE SWITCH (WAGON)

Refer to 6-2 [W8B3] as for inspection of rear gate switch.
NOTE:
The rear gate switch is combined with the luggage room
light switch.
9. SECURITY INDICATOR LIGHT

1) Remove security indicator light.
2) Check continuity between terminals of security indicator
light.
3) If there is no continuity, the indicator light will be fail-
ured.
Terminals: No. 2 — No. 4
B6M0382A
10. SECURITY CONTROL MODULE

Refer to 6-2 [K600]: “6. SECURITY SYSTEM” for inspec-
tion of security control module.
58
22. Security System
C: FUNCTION TEST
1. SECURITY SYSTEM OPERATION
1) Fully open all the door windows.
2) Turn the ignition switch to OFF and remove ignition key
from ignition switch.
3) Get out of the vehicle and lock the driver’s door using a
ignition key.
4) Check that the security indicator light illuminates.

5) When the security indicator light illuminates, wait for 30
seconds.
After 30 seconds, check that the light starts repeating 0.2
sec. ON and 2.4 sec. OFF sequence.
6) Unlock the driver’s door using the inside lock knob and
open the door.
Ensure that:
(1) the horn sounds and headlights flash intermittently
at 0.2 sec. ON and 0.6 sec. OFF. intervals, and
(2) the engine will not start even if the ignition switch
is turned to START.
7) Unlock the driver’s door one time using the ignition key.
Ensure the horn and headlights turn off.
8) Close and lock the driver’s door without using a ignition

key. (Set the inside lock knob to LOCK and then close the
door while lifting the outer handle).
Check that the security indicator light illuminates continu-
ously.
9) Within 30 seconds after the above step 8), unlock the

rear LH door using the inside lock knob and open the door.
Check that the security indicator light flashes at 0.5 sec.
intervals.
10) Close the rear LH door and lock the door using the
inside lock knob.
ously.
11) Perform the above steps 9) and 10) on the rear RH

door and front RH door.
12) Within 30 seconds after above step 11) has been

finished, pull the engine hood opener lever and open the
engine hood.
intervals.
13) Close the engine hood completely.
ously.
59
22. Security System
14) Within 30 seconds after the above step 13), pull the
trunk lid opener lever and open the trunk lid (SEDAN); or
unlock the rear gate by operating the driver’s door inside
lock knob and open the rear gate (WAGON).
intervals.
15) Close the trunk lid completely (SEDAN); or close the
rear gate and lock by locking the driver’s door using a igni-
tion key (WAGON).
ously.
16) When the security indicator light illuminates
continuously, wait for 30 seconds.
17) Unlock the trunk lid (SEDAN) or rear gate (WAGON)

using a ignition key and open.
Check that the horn and headlights do not operate.
18) Close the trunk lid (SEDAN) or rear gate (WAGON).
19) Unlock and then lock the driver’s door using a ignition
key and wait for 30 seconds.
20) Only WAGON model; unlock and then lock the rear
gate using a ignition key and wait for 30 seconds.
21) Unlock the front RH door using a ignition key and open
the door.
Check that the horn and headlights do not operate.
After finishing the above checks, ensure that security sys-
tem’s function is correct.
60
DIAGNOSTICS 6-2
1. Starter Interlock System (MT Model)

A: DIAGNOSTICS PROCEDURE
1. Check main power supply for starter motor. Not OK 쐌 Recharge the battery.
왘
쐌 Repair or replace wiring harness.
OK
왔
2. Check power supply for magnet coil of starter OK Repair or replace starter motor.
왘
motor.
Not OK
왔
3. Check power supply for starter interlock relay. Not OK Repair or replace wiring harness.
왘
OK
왔
Not OK
4. Check starter interlock relay. 왘
Replace starter interlock relay.
OK
왔
5. Check clutch switch. Not OK
왘
Adjust or replace clutch switch.
OK
왔
6. Check harness connector between starter Not OK
왘
Repair or replace wiring harness.
interlock relay and starter motor.
OK
왔
왘
interlock relay and clutch switch.
OK
왔
Not OK
8. Check ground circuit of clutch switch. 왘
OK
왔
System is OK
61
6-2 DIAGNOSTICS
1. CHECK MAIN POWER SUPPLY FOR STARTER

MOTOR.
Measure voltage between starter motor terminal B and
body.
Connector & terminal / Specified voltage:
Terminal B — Body / 10 V, or more
B6M0383A
2. CHECK POWER SUPPLY FOR MAGNET COIL OF

STARTER MOTOR.
1) Disconnect all connectors from starter motor.
2) Turn ignition switch to ST (START).
3) Depress clutch pedal.
4) Measure voltage between starter motor terminal S con-
nector and body.
(B14) Terminal S — Body / 10 V, or more
B6M0384A
3. CHECK POWER SUPPLY FOR STARTER

INTERLOCK RELAY.
1) Disconnect all connectors from starter motor.
2) Disconnect connector of starter interlock relay.
3) Turn ignition switch to ST (START).
4) Measure voltage between starter interlock relay con-
nector and body.
(B105) No. 2 — Body / 10 V, or more
B6M0385A (B105) No. 4 — Body / 10 V, or more
4. CHECK STARTER INTERLOCK RELAY.
1) Disconnect connector of starter interlock relay.
No. 1.
table below:
No. 3 and No. 4
No. 1 and No. 2
B6M0386A
62
DIAGNOSTICS 6-2
5. CHECK CLUTCH SWITCH.

1) Disconnect connector of clutch switch.
2) Check continuity between terminals when clutch pedal
is depressed/released.
Terminals / Specified resistance:
No. 1 — No. 2 / 10 Ω, max.
(Without pedal depressing.)
/ 1 MΩ, min. (Pedal depressing.)
G6M0184
6. CHECK HARNESS CONNECTOR BETWEEN

STARTER INTERLOCK RELAY AND STARTER
MOTOR.
1) Disconnect connectors of starter interlock relay and
starter motor.
2) Measure resistance of harness connector between
starter interlock relay and starter motor.
Connector & terminal / Specified resistance:
(B105) No. 3 — (B14) terminal S / 10 Ω, max.
B6M0387A

STARTER INTERLOCK RELAY AND CLUTCH SWITCH.
1) Disconnect connectors of starter interlock relay and
clutch switch.
starter interlock relay and clutch switch.
(B105) No. 1 — (B106) No. 2 / 10 Ω, max.
B6M0388A
8. CHECK GROUND CIRCUIT OF CLUTCH SWITCH.

1) Disconnect connector of clutch switch.
clutch switch and body.
(B106) No. 1 — Body / 10 Ω, max.
B6M0389A
63
6-2 DIAGNOSTICS
2. AT Shift Lock System

A: WIRING DIAGRAM
B6M0466
64
DIAGNOSTICS 6-2
B: BASIC DIAGNOSTICS CHART
Turn ignition switch ON.
왔
Check that shift lever does not move from “P” to any Not OK Conduct diagnostics procedure No. 1. <Ref. to
왘
other position. [K2C0].>
OK
왔
Check if shift lever moves from “P” to any other Not OK Conduct diagnostics procedure No. 2. <Ref. to
왘
position while depressing brake pedal. [K2D0].>
OK
왔
Move shift lever to “N” and turn ignition switch OFF.
왔
Check that ignition key cannot be removed from slot Not OK
왘
Conduct diagnostics procedure No. 3. <Ref. to
properly. [K2E0].>
OK
왔
Check if ignition key can be removed with shift lever Not OK
왘
Conduct diagnostics procedure No. 4. <Ref. to
moved to “P”. [K2F0].>
OK
왔
System is OK.
65
6-2 DIAGNOSTICS
C: DIAGNOSTICS PROCEDURE No. 1
Not OK
Check that stop lights do not remain on when brake 왘
Check stop light system.
pedal is released.
OK
왔
Disconnect connector from shift lock control module.
왔
Check that shift lock does not occur when shift lever Not OK Replace shift lock control module.
왘
is moved to “P”.
OK
왔
Disconnect connector from “P” position switch.
왔
Disconnect connector from shift lock solenoid.
왔
Not OK
Check that shift lock does not occur when shift lever 왘
Short in wiring harness of shift lock solenoid.
is moved to “P”.
OK
왔
Check selector lever assembly.
66
DIAGNOSTICS 6-2
D: DIAGNOSTICS PROCEDURE No. 2 (SHIFT

LOCK DOES NOT RELEASE.)
Not OK
Check if stop light comes on when brake pedal is 왘 Check stop light system.
depressed.
OK
왔
Not OK
Check if voltage between shift lock control module 왘 Repair or replace wiring harness or faulty connector
terminal No. 4 and body is at least 10 V when brake between stop light switch and shift lock control
pedal is depressed. module.
OK
왔
Not OK
Check if voltage between shift lock control module 왘 Check fuse.
terminal No. 1 and body is at least 10 V when Repair or replace wiring harness or faulty connector
ignition switch is turned ON. between ignition switch and shift lock control
module.
OK
왔
Turn ignition switch OFF.
Disconnect connector from shift lock control module.
왔
Not OK
Check if continuity exists between terminal No. 2 of 왘 Check inhibitor switch or repair wiring harness.
shift lock control module connector and body when
shift lever is set at “P”.
OK
왔
Not OK
Check if continuity exists between terminal No. 5 of 왘 Check “P” position switch or repair wiring harness.
shift lock control module connector and body when
shift lever is set at “P”.
OK
왔
Measure resistance between terminal No. 1 of shift
lock control module connector and body.
왔
Not OK
Resistance is less than 20 Ω. 왘 Shift lock solenoid circuit is shorted. Repair or
replace wiring harness or faulty connector between
OK shift lock solenoid and shift lock control module.
왔
Not OK
Resistance is at least 10 Ω. 왘 Shift lock solenoid is shorted or poorly grounded.
* After repairs, recheck solenoid operation.
OK If still faulty, replace shift lock control module.
왔
Not OK
Check if resistance between terminal No. 10 of shift 왘 Shift lock control module ground circuit open or poor
lock control module connector and body is less than connector contact.
10 Ω.
OK
왔
Replace shift lock control module.
67
6-2 DIAGNOSTICS
E: DIAGNOSTICS PROCEDURE No. 3 (KEY

INTERLOCK DOES NOT OPERATE.)
Not OK
Check if shift lock operates properly. 왘
Check diagnostics procedure “No. 1” or “No. 2”.
OK
왔
Not OK
Check if voltage between shift lock control module 왘
Faulty key switch.
terminal No. 8 and body is at least 10 V when Repair or replace wiring harness or faulty connector
ignition key is inserted in its slot. between fuse box and shift lock control module.
OK
왔
Check if voltage between shift lock control module Not OK Repair or replace wiring harness or faulty connector
왘
terminal No. 7 and body is at least 10 V when between ignition switch and shift lock control
ignition switch is set to ACC. module.
OK
왔
Disconnect connector from shift lock control module. Not OK
왘
Key lock solenoid circuit open. Repair or replace
Check if resistance between terminal No. 9 and wiring harness or faulty connector between key lock
terminal No. 11 of shift lock control module solenoid and shift lock control module.
connector is less than 8 Ω.
OK
왔
Voltage is at least 4 V. (*) Not OK
왘
Key lock solenoid is shorted.
Repair or replace wiring harness or faulty connector
OK between key lock solenoid and shift lock control
왔 module.
Not OK * After repairs, recheck for proper operation.
Check if resistance between terminal No. 11 of shift 왘 If still faulty, replace shift lock control module.
lock control module connector and body is at least 1
MΩ.
OK
왔
*: When conducting operational checks of the key lock solenoid, do not apply 12 V to solenoid for more than one second, since
this may break solenoid circuit.
68
DIAGNOSTICS 6-2
F: DIAGNOSTICS PROCEDURE No. 4 (KEY

INTERLOCK DOES NOT RELEASE.)
Not OK
Check if shift lock operates properly. 왘
Check diagnostics procedure “No. 1” or “No. 2”.
OK
왔
Not OK
Check if voltage between shift lock control module 왘
Faulty key switch. Repair or replace wiring harness
terminal No. 8 and body is at least 10 V when or faulty connector between fuse box and shift lock
ignition key is inserted in its slot. control module.
OK
왔
Check if voltage between shift lock control module Not OK Repair or replace wiring harness or faulty connector
왘
terminal No. 7 and body is at least 10 V when between ignition switch and shift lock control
ignition switch is set to ACC. module.
OK
왔
Disconnect connector from shift lock control module. Not OK
왘
Key lock solenoid circuit open.
Check if resistance between terminal No. 9 and Repair or replace wiring harness or faulty connector
terminal No. 11 of shift lock control module between key lock solenoid and shift lock control
connector is less than 8 Ω. (*) module.
OK
왔
Voltage is at least 4 V. Not OK
왘
Key lock solenoid is shorted.
OK between key lock solenoid and shift lock control
module.
* After repairs, recheck for proper operation.
If still faulty, replace shift lock control module.
왔
Check if resistance between terminal No. 9 of shift Not OK
왘
lock control module connector and body is at least 1 between key lock solenoid and shift lock control
MΩ. module.
* After repairs, recheck for proper operation.
OK If still faulty, replace shift lock control module.
왔
*: When conducting operational checks of the key lock solenoid, do not apply 12 V to solenoid for more than one second, since
this may break solenoid circuit.
69
6-2 DIAGNOSTICS
If speedometer does not operate, or operates abnormally,
check combination meter circuit (shown in flow chart as
described below).
CAUTION:
Make sure that trouble code of vehicle speed sensor 2
system appears in electrical system on-board diagno-
sis.
Speedometer does not operate, or operates

abnormally.
왔
1. Check power supply for combination meter. Not OK 쐌 Check for disconnection of the combination meter
왘
connector terminal.
OK 쐌 Check for open circuit between combination meter
and battery.
, Repair or replace wiring harness.
왔
Not OK
2. Check ground circuit of combination meter. 왘
OK
왔
3. Check harness connector between Not OK
왘
combination meter and vehicle speed sensor
2.
OK
왔
Not OK
4. Check vehicle speed sensor 2. 왘
Replace vehicle speed sensor 2.
OK
왔
Failure of the speedometer.
70
DIAGNOSTICS 6-2
1. CHECK POWER SUPPLY FOR COMBINATION

METER.
1) Remove combination meter.
2) Turn ignition switch to ON.
3) Measure voltage at combination meter connector termi-
nal.
(i14) No. 11 — Body / 10 V, or more
B6M0530A
2. CHECK GROUND CIRCUIT OF COMBINATION

METER.
1) Turn ignition switch to OFF.
combination meter and body.
(i12) No. 1 — Body / 10 Ω, max.
B6M0252B

COMBINATION METER AND VEHICLE SPEED
SENSOR 2.
1) Disconnect connector from vehicle speed sensor 2.
vehicle speed sensor 2 and combination meter.
(B17) No. 1 — (i11) No. 2 / 10 Ω, max.
(B17) No. 2 — (i11) No. 3 / 10 Ω, max.
B6M0294B
4. CHECK VEHICLE SPEED SENSOR 2.

NOTE:
쐌 If resistance between terminals of vehicle speed sensor
2 is out of specification, the sensor may have a failure.
쐌 If resistance is OK and voltage between terminals of
vehicle speed sensor 2 is out of specification, mechanical
trouble may be present between vehicle speed sensor 2
and speedometer shaft in transmission.
71
6-2 DIAGNOSTICS
1) Disconnect connector from vehicle speed sensor 2.

2) Measure resistance between terminals of vehicle speed
sensor 2.
No. 1 — No. 2 / 350 — 450 Ω
B3M0289
WARNING:
Be careful not to be caught up by the running wheels.
3) Set the vehicle on free roller, or lift-up the vehicle and
support with safety stands.
4) Drive the vehicle at speed greater than 20 km/h (12
MPH).
5) Measure voltage between terminals of vehicle speed
sensor 2.
Terminals / Specified voltage:
B3M0256
No. 1 — No. 2 / 5 V, min. (AC range)
쐌 Using an oscilloscope:
(1) Turn ignition switch to OFF.
(2) Set oscilloscope to vehicle speed sensor 2.
(3) Drive the vehicle at speed greater than 20 km/h (12
MPH).
(4) Measure signal voltage.
Specified voltage (V): 5 V, min.
B3M0257
B3M0254A
72
DIAGNOSTICS 6-2
4. Power Window
4. Power Window
A: DIAGNOSTICS PROCEDURE-1
Trouble symptom A: All door windows do not operate.
1. Check fuse and power supply. Not OK 쐌 Replace fuse or circuit breaker.
왘
OK
왔
2. Check power window relay. Not OK Replace power window relay.
왘
OK
왔
Not OK
3. Check ground circuit of power window relay. 왘
OK
왔
Not OK
4. Check harness connector between power 왘
window relay and power window main switch
(driver’s door switch).
OK
왔
Not OK
5. Check power window main switch. 왘
Replace power window main switch.
OK
왔
Not OK
6. Check ground circuit of power window main 왘
switch.
OK
왔
System is OK.
1. CHECK FUSE AND POWER SUPPLY.

1) Check fuse No. 15.
2) Disconnect connector of power window relay.
4) Measure voltage between power window relay connec-
tor and body.
B6M0390A
73
6-2 DIAGNOSTICS
4. Power Window
2. CHECK POWER WINDOW RELAY.

No. 3.
table below:
No. 2 and No. 4
No. 1 and No. 3
B6M0391A
3. CHECK GROUND CIRCUIT OF POWER WINDOW

RELAY.
power window relay and body.
(B42) No. 3 — Body / 10 Ω, max.
B6M0392A

POWER WINDOW RELAY AND POWER WINDOW
MAIN SWITCH (DRIVER’S DOOR SWITCH).
1) Disconnect connectors of power window relay and
power window main switch.
power window relay and power window main switch.
(B42) No. 4 — (D7) No. 7 / 10 Ω, max.
B6M0393A
5. CHECK POWER WINDOW MAIN SWITCH.

Refer to 6-2 [W16B1] for inspection of power window main
switch.
74
DIAGNOSTICS 6-2
4. Power Window

MAIN SWITCH.
1) Disconnect connector of power window main switch.
power window main switch and body.
(D7) No. 12 — Body / 10 Ω, max.
B6M0394A
75
6-2 DIAGNOSTICS
4. Power Window
B: DIAGNOSTICS PROCEDURE-2
Trouble symptom B: Only driver’s door window does not
operate.
1. Check power supply for power window main Not OK Go to diagnostics procedure of trouble symptom A.
왘
switch. <Ref. to [K4A0].>
OK
왔
Not OK
2. Check power window main switch (driver’s 왘
door switch).
OK
왔
Not OK
switch.
OK
왔
4. Check driver’s door window motor. Not OK
왘
Replace power window motor.
OK
왔
5. Check harness connector between power Not OK
왘
window main switch and driver’s door
window motor.
OK
왔
쐌 System circuit is OK.
쐌 Mechanical trouble may be caused in door
window system such as break of window
regulator.
1. CHECK POWER SUPPLY FOR POWER WINDOW

MAIN SWITCH.
3) Measure voltage between power window main switch
connector and body.
(D7) No. 7 — Body / 10 V, or more
B6M0395A
2. CHECK POWER WINDOW MAIN SWITCH

(DRIVER’S DOOR SWITCH).
switch.
76
DIAGNOSTICS 6-2
4. Power Window

MAIN SWITCH.
(D7) No. 12 — Body / 10 Ω, max.
B6M0394A
4. CHECK DRIVER’S DOOR WINDOW MOTOR.

1) Disconnect connector of power window motor (driver’s
door).
nector.

POWER WINDOW MAIN SWITCH AND DRIVER’S
DOOR WINDOW MOTOR.
1) Disconnect connectors of power window main switch
and power window motor (driver’s door).
power window main switch and power window motor.
LHD model:
B6M0396A (D7) No. 8 — (D3) No. 2 / 10 Ω, max.
(D7) No. 13 — (D3) No. 1 / 10 Ω, max.
RHD model:
(D7) No. 6 — (D3) No. 2 / 10 Ω, max.
(D7) No. 11 — (D3) No. 1 / 10 Ω, max.
77
6-2 DIAGNOSTICS
4. Power Window
C: DIAGNOSTICS PROCEDURE-3
Trouble symptom C: One or more of passenger’s door win-
dow do not operate.
1. Check power supply for power window sub Not OK Repair or replace wiring harness.
왘
switch which is out of order.
OK
왔
Not OK
2. Check power window sub switch which is out 왘
Replace power window sub switch.
of order.
OK
왔
Not OK
3. Check power window motor which is out of 왘
Replace power window motor.
order.
OK
왔
왘
window sub switch and power window motor.
OK
왔
왘
window sub switch and main switch.
OK
왔
6. Check power window main switch. Not OK
왘
OK
왔
Not OK
switch.
OK
왔
쐌 System circuit is OK.
쐌 Mechanical trouble may be caused in door
window system such as break of window
regulator.
78
DIAGNOSTICS 6-2
4. Power Window
1. CHECK POWER SUPPLY FOR POWER WINDOW

SUB SWITCH WHICH IS OUT OF ORDER.
1) Disconnect connector of power window sub switch.
3) Measure voltage between power window sub switch
connector and body.
(D17) No. 5 — Body / 10 V, or more
(Front passenger)
B6M0397A (D31) No. 5 — Body / 10 V, or more (Rear RH)
(D25) No. 5 — Body / 10 V, or more (Rear LH)
2. CHECK POWER WINDOW SUB SWITCH WHICH IS

OUT OF ORDER.
Refer to 6-2 [W16B2] for inspection of power window sub
switch.
3. CHECK POWER WINDOW MOTOR WHICH IS OUT

OF ORDER.
1) Disconnect connector of power window motor.
nector.

POWER WINDOW SUB SWITCH AND POWER
WINDOW MOTOR.
1) Disconnect connectors of power window sub switch and
power window motor.
power window sub switch and power window motor.
(D17) No. 2 — (D13) No. 1 / 10 Ω, max.
B6M0398A (Front passenger)
(D17) No. 4 — (D13) No. 2 / 10 Ω, max.
(Front passenger)
(D31) No. 2 — (D30) No. 1 / 10 Ω, max. (Rear RH)
(D25) No. 2 — (D24) No. 1 / 10 Ω, max. (Rear LH)
79
6-2 DIAGNOSTICS
4. Power Window

POWER WINDOW SUB SWITCH AND MAIN SWITCH.
1) Disconnect connectors of power window sub switch and
main switch.
power window sub switch and main switch.
LHD model:
(D17) No. 1 — (D7) No. 9 / 10 Ω, max.
(D17) No. 3 — (D7) No. 14 / 10 Ω, max.
(Front passenger)
RHD model:
(D17) No. 1 — (D7) No. 10 / 10 Ω, max.
(Front passenger)
(D17) No. 3 — (D7) No. 5 / 10 Ω, max.
B6M0468A
6. CHECK POWER WINDOW MAIN SWITCH.

switch.

MAIN SWITCH.
(D7) No. 12 — Body / 10 Ω, max.
B6M0394A
80
DIAGNOSTICS 6-2

1. Check fuse and power supply for remote Not OK 쐌 Replace fuse.
왘
controlled rearview mirror switch. 쐌 Repair or replace wiring harness.
OK
왔
2. Check ground circuit of rearview mirror Not OK Repair or replace wiring harness.
왘
switch.
OK
왔
Not OK
3. Check rearview mirror switch. 왘
Replace rearview mirror switch.
OK
왔
4. Check harness connector between rearview Not OK Repair or replace wiring harness.
왘
mirror switch and rearview mirror (RH and
LH).
OK
왔
Not OK
5. Check rearview mirror motor. 왘
Replace rearview mirror.
OK
왔
System is OK.
1. CHECK FUSE AND POWER SUPPLY FOR REMOTE

CONTROLLED REARVIEW MIRROR SWITCH.
2) Disconnect connector of rearview mirror switch.
4) Measure voltage between rearview mirror switch con-
nector and body.
B6M0400A
2. CHECK GROUND CIRCUIT OF REARVIEW

MIRROR SWITCH.
1) Disconnect connector of rearview mirror switch.
rearview mirror switch and body.
(i6) No. 2 — Body / 10 Ω, max.
B6M0401A
81
6-2 DIAGNOSTICS
3. CHECK REARVIEW MIRROR SWITCH.

Refer to 6-2 [W18B1] for inspection of rearview mirror
switch.

REARVIEW MIRROR SWITCH AND REARVIEW
MIRROR (RH AND LH).
1) Disconnect connectors of rearview mirror switch and
rearview mirror.
rearview mirror switch and rearview mirror.
LHD model:
B6M0402A (i6) No. 1 — (D15) No. 1 / 10 Ω, max. (RH)
(i6) No. 8 — (D15) No. 2 / 10 Ω, max. (RH)
(i6) No. 6 — (D15) No. 3 / 10 Ω, max. (RH)
(i6) No. 1 — (D 5) No. 1 / 10 Ω, max. (LH)
(i6) No. 9 — (D 5) No. 2 / 10 Ω, max. (LH)
(i6) No. 7 — (D 5) No. 3 / 10 Ω, max. (LH)
RHD model:
(i6) No. 1 — (D5) No. 1 / 10 Ω, max. (RH)
(i6) No. 8 — (D5) No. 2 / 10 Ω, max. (RH)
(i6) No. 6 — (D5) No. 3 / 10 Ω, max. (RH)
(i6) No. 1 — (D15) No. 1 / 10 Ω, max. (LH)
B6M0469A (i6) No. 9 — (D15) No. 2 / 10 Ω, max. (LH)
(i6) No. 7 — (D15) No. 3 / 10 Ω, max. (LH)
5. CHECK REARVIEW MIRROR MOTOR.

Refer to 6-2 [W18B2] for inspection of rearview mirror
motor.
82
DIAGNOSTICS 6-2
6. Security System
6. Security System
A: ELECTRICAL COMPONENTS LOCATION
B6M0403A
쎻
1 Security control module 쎻
9 Rear gate switch (WAGON)
쎻
2 Security indicator light 쎻
10 LH door key cylinder lock/unlock switch (built-in tamper
쎻
3 RH door key cylinder lock/unlock switch (built-in tamper switch)
switch) 쎻
11 Starter interrupt relay
쎻
4 Door switch 쎻
12 Headlight alarm relay
쎻
5 Door lock/unlock switch 쎻
13 Ignition switch (ACC position)
쎻
6 Trunk lid key cylinder unlock switch (SEDAN) (built-in tamper 쎻
14 Engine hood switch
switch) 쎻
15 Horn
쎻
7 Trunk lid switch (SEDAN) 쎻
16 Headlight
쎻
8 Rear gate key cylinder lock/unlock switch (WAGON)
83
6-2 DIAGNOSTICS
6. Security System
B: SCHEMATIC
B6H0319
84
DIAGNOSTICS 6-2
6. Security System
C: CONTROL MODULE I/O SIGNAL
B6M0405
Measuring conditions and I/O signals

Content Terminal No.
(Ignition switch ACC position)
1 쐌 Battery voltage is present when all doors and rear gate (WAGON) are locked.
Door lock/unlock switch
(INPUT) 쐌 “0” volt is present when one of the doors or rear gate (WAGON) is unlocked.
2 쐌 “0” volt is present when key cylinder is turned to LOCK position.
Key cylinder lock switch
(INPUT) 쐌 Battery voltage is present when key cylinder is in positions other than LOCK.
3 쐌 Battery voltage is present when key cylinder switch is installed to key cylinder.
Tamper switch
(INPUT) 쐌 “0” volt is present when key cylinder switch is removed from key cylinder.
4 쐌 Battery voltage is present when all doors are closed.
Door switch
(INPUT) 쐌 “0” volt is present when one of the doors is open.
5 쐌 Battery voltage is present when ignition switch is turned ACC or ON.
Starter interrupt relay
(OUTPUT) 쐌 “0” volt is present when security system is in alarm state.
6 쐌 Battery voltage is present when ignition switch is turned ACC or ON.
Ignition switch (ACC)
(INPUT) 쐌 “0” volt is present when ignition switch is turned OFF.
7 쐌 Battery voltage is present when indicator light goes off.
Security indicator light
(OUTPUT) 쐌 “0” volt is present when indicator light illuminates.
Power supply (back-up) 8 Battery voltage is constantly present.
Ground 9 —
10 쐌 Battery voltage is present when engine hood is closed.
Engine hood switch
(INPUT) 쐌 “0” volt is present when engine hood is open.
Trunk lid switch (SEDAN) 11 쐌 Battery voltage is present when trunk lid or rear gate is closed.
Rear gate switch (WAGON) (INPUT) 쐌 “0” volt is present when trunk lid or rear gate is open.
쐌 Battery voltage is present when ignition switch is turned ACC or ON.
12
Headlight alarm relay 쐌 “0” volt and battery voltage repeats in alarm state. (Headlights flash intermittently
(OUTPUT)
at 0.2 sec. ON and 0.6 sec. OFF intervals).
쐌 Battery voltage is present when ignition switch is turned ACC or ON.
13
Horn relay 쐌 “0” volt and battery voltage repeats in alarm state. (Horn sounds intermittently at
(OUTPUT)
0.2 sec. ON and 0.6 sec. OFF intervals.)
14 쐌 “0” volt is present when key cylinder is turned to UNLOCK position.
Key cylinder unlock switch
(INPUT) 쐌 Battery voltage is present when key cylinder is in positions other than UNLOCK.
쐌 “0” volt is present when trunk lid key cylinder is turned to UNLOCK position.
Trunk lid key cylinder unlock 15
쐌 Battery voltage is present when trunk lid key cylinder is in positions other than
switch (SEDAN) (INPUT)
UNLOCK.
85
6-2 DIAGNOSTICS
6. Security System
D: BASIC DIAGNOSTICS PROCEDURE

Start security system check.
왔
Fully open all door windows and turn ignition switch OFF.
왔
Take key out of ignition, exit vehicle and lock driver’s door.
왔 The light does not

illuminate.
Indicator light illuminates. Check indicator harness.
왘 Check security indicator light.
OK The light flashes. Check driver’s door key cylinder lock/unlock switch.
Check security control module.
Check whether switch input signal remains UNLOCK.
Check wiring harness.
왔
Check switch input signals.
(Harnesses and switches separately)
(Tamper, door, hood, trunk and rear gate
switch)Check security control module.
왔
Wait for 30 seconds.
왔
Not OK
Indicator light flashes at long intervals (0.2 sec. ON and 2.4 sec. Check security control module.
OFF). 왘
왔 OK
Unlock driver’s door using the inside lock knob and open door.
왔
All are not OK.
The horn sounds and headlights flash intermittently at 0.2 sec. ON Check driver’s door switch.
and 0.6 sec. OFF intervals. 왘 Check wiring harness.
The engine will not start even if the ignition switch is turned to Check security control module.
START. Indicator lamp goes out.
Horn is not OK. Not OK
OK Starter motor runs. Check horn Check horn.
왘 operation by 왘 Check horn relay.
pushing horn pad
on steering wheel.
왔 OK
Check harness between horn relay and security control module.
Headlights are not
OK. Not OK
Check headlights Check headlight
왘 operation by 왘 bulbs.
turning light switch Check combination
ON/OFF. switch.
Check headlight
OK relay.
왔 왔
Check starter interrupt relay. Check headlight alarm relay.
Check wiring harness. Check security control module.
Check security control module. Check wiring harness.
왔
The alarm system continues to operate for 150 seconds.
왔 OK 왔 Not OK
Not OK
The horn and Check security
headlights turn off. 왘 control module.
The starter motor
does not run.
왔 OK
Unlock the driver’s door using ignition key.
왔
Continues to next step.
86
DIAGNOSTICS 6-2
6. Security System
From the previous step

왔
Not OK
Starter motor runs. 왘 Check starter interrupt relay.
Check wiring harness.
OK Check security control module.
Check driver’s door unlock switch.
왔
Lock the driver’s door without using a ignition key. (Set the inside
lock knob to LOCK and then close the door while lifting the outer
handle).
왔
Within 30 seconds after the above step, open rear LH door.
왔
Not OK
Indicator light flashes with short intervals (1 Hz). 왘 Check rear LH door switch.
Check rear LH door switch harness.
왔
Close and lock door.
왔
Indicator light illuminates continuously.
OK
왔
Not OK
Perform the above steps also on the rear RH door and front RH 왘 Check rear and front RH door switches.
door. Check wiring harnesses.
OK
왔
Pull engine hood opener lever and open engine hood.
왔
Not OK
Indicator light flashes at short intervals (1 Hz). 왘 Check hood switch.
Check hood switch harness.
왔
Close engine hood.
왔
WAGON
Indicator light illuminates continuously. 왘 Unlock rear gate by operating driver’s door inside lock knob and
open rear gate.
SEDAN
왔 왔
Pull trunk opener lever and open trunk lid. Indicator light flashes at short intervals (1 Hz).
OK Not OK
왔 왔
Indicator light flashes at short intervals (1 Hz). Check rear gate switch.
Check rear gate switch harness.
OK Not OK Check security control module.
왔 왔
Check trunk switch. Close rear gate and lock by locking driver’s door using a
Check trunk switch harness. ignition key.
왔 왔
Close trunk lid. Indicator light illuminates continuously.
왔 왔
Indicator light illuminates continuously. Wait for 30 seconds.
왔 왔
Wait for 30 seconds. Indicator light flashes at long intervals (0.2 sec. ON and 2.4
sec. OFF).
왔 왔
Continues to next step. Continues to next step.
87
6-2 DIAGNOSTICS
6. Security System
From the previous step. From the previous step.
왔 왔
Indicator light flashes at long intervals (0.2 sec. ON and 2.4 sec. Unlock rear gate using a ignition key and open.
OFF).
왔
Unlock trunk lid using a ignition key and open.
왔 왔
The alarm system does not operate. The alarm system does not operate.
OK Not OK OK Not OK
왔 왔
Check trunk unlock switch. Check rear gate unlock switch.
Check trunk unlock switch harness. Check rear gate unlock switch harness.
Check security control module. Check security control module.
왔 왔
Close trunk lid. Close rear gate.
왔
Lock rear gate using a ignition key.
왔 왔
Indicator light illuminates continuously. Indicator light illuminates continuously.
OK Not OK
왔
Check rear gate lock switch.
Check rear gate lock switch harness.
왔
Wait for 30 seconds. 왗
왔
Indicator light flashes at long intervals (0.2 sec. ON and 2.4 sec.
OFF).
왔
Unlock front RH door using a ignition key and open.
왔
Not OK
The alarm system does not operate. 왘 Check front RH door key cylinder unlock switch.
Check front RH door key cylinder unlock switch harness.
왔
Close front RH door and lock using a ignition key.
왔
Not OK
Indicator light illuminates continuously. 왘 Check front RH door key cylinder lock switch.
Check front RH door key cylinder lock switch harness.
왔
Finish checking security system.
88
DIAGNOSTICS 6-2
6. Security System
E: DIAGNOSTICS PROCEDURE FOR

SECURITY CONTROL MODULE POWER
SUPPLY/GROUND CIRCUIT
Not OK 쐌 Replace fuse.
1. Check fuse and power supply circuit. 왘
OK
왔
Not OK
2. Check ground circuit between security control 왘
module and body.
OK
왔
Go to next step on basic diagnostics procedure.
<Ref. to [K6D0].>
1. CHECK FUSE AND POWER SUPPLY CIRCUIT.

2) Measure voltage between main fuse box connector and
body.
(F35) No. 2 — Body / 10 V, or more
B6M0504A

4) Measure voltage between security control module con-
nector and body.
B6M0448A

6) Turn ignition switch to ACC.
7) Measure voltage between fuse and relay box connec-
tor and body.
B6M0505A
89
6-2 DIAGNOSTICS
6. Security System

nector and body.
B6M0452A
2. CHECK GROUND CIRCUIT BETWEEN SECURITY

CONTROL MODULE AND BODY.
1) Turn ignition switch to OFF.
2) Disconnect connector of security control module.
security control module and body.
(B93) No. 9 — Body / 10 Ω, max.
B6M0497A
90
DIAGNOSTICS 6-2
6. Security System
F: DIAGNOSTICS PROCEDURE FOR

SECURITY INDICATOR LIGHT AND
INDICATOR LIGHT CIRCUIT
Not OK
1. Check security indicator light. 왘
Replace indicator light.
OK
왔
2. Check power supply for indicator light. Not OK Repair or replace wiring harness.
왘
OK
왔
3. Check harness connector between security Not OK Repair or replace wiring harness.
왘
indicator light and security control module.
OK
왔
<Ref. to [K6D0].>
1. CHECK SECURITY INDICATOR LIGHT.

1) Remove security indicator light.
2) Measure resistance between security indicator light
connector terminals.
No. 2 — No. 4 / Approx. 120 Ω
B6M0382A
2. CHECK POWER SUPPLY FOR INDICATOR LIGHT.

1) Disconnect connector of security indicator light.
2) Measure voltage between security indicator light con-
nector and body.
B6M0443A

SECURITY INDICATOR LIGHT AND SECURITY
CONTROL MODULE.
1) Disconnect connectors of security indicator light and
security control module.
security indicator light and security control module.
(i8) No. 4 — (B93) No. 7 / 10 Ω, max.
B6M0498A
91
6-2 DIAGNOSTICS
6. Security System
G: DIAGNOSTICS PROCEDURE FOR DOOR

SWITCH SIGNAL
1. Check door switch input signal for security OK Go to next step on basic diagnostics procedure.
왘
control module. <Ref. to [K6D0].>
Not OK
왔
Not OK
2. Check door switch. 왘
Replace door switch.
OK
왔
Repair or replace wiring harness between door
switch and security control module.
1. CHECK DOOR SWITCH INPUT SIGNAL FOR

SECURITY CONTROL MODULE.
1) Remove security control module without disconnecting
connector.
2) Turn door switch ON/OFF and measure voltage
between security control module connector and body.
(B93) No. 4 — Body / 10 V, or more (Door closed)
/ 1 V, max. (Door opened)
B6M0453A
NOTE:
When one of the doors is open, the voltage may be 1 V,
max.
2. CHECK DOOR SWITCH.

Refer to 6-2 [W8B1] for inspection of door switch.
NOTE:
The door switch is used for interior light also.
92
DIAGNOSTICS 6-2
6. Security System
H: DIAGNOSTICS PROCEDURE FOR ENGINE

HOOD SWITCH SIGNAL
1. Check engine hood switch input signal for OK Go to next step on basic diagnostics procedure.
왘
security control module. <Ref. to [K6D0].>
Not OK
왔
Not OK
2. Check engine hood switch. 왘
Replace engine hood switch.
OK
왔
Repair or replace wiring harness between engine
hood switch and security control module.
1. CHECK ENGINE HOOD SWITCH INPUT SIGNAL

FOR SECURITY CONTROL MODULE.
connector.
2) Turn engine hood switch ON/OFF and measure voltage
between security control module connector and body.
(B93) No. 10 — Body / 10 V, or more (Hood
closed)
B6M0451A / 1 V, max. (Hood opened)
2. CHECK ENGINE HOOD SWITCH.
Refer to 6-2 [W22B3] for inspection of engine hood switch.
93
6-2 DIAGNOSTICS
6. Security System
I: DIAGNOSTICS PROCEDURE FOR TRUNK

LID SWITCH (SEDAN) OR REAR GATE
SWITCH (WAGON) SIGNAL
OK
1. Check trunk lid switch (SEDAN) or rear gate 왘
switch (WAGON) input signal for security <Ref. to [K6D0].>
control module.
Not OK
왔
2. Check trunk lid switch (SEDAN) or rear gate Not OK Replace trunk lid switch (or rear gate switch).
왘
switch (WAGON).
OK
왔
Repair or replace wiring harness between trunk lid
switch (or rear gate switch) and security control
module.
1. CHECK TRUNK LID SWITCH (SEDAN) OR REAR

GATE SWITCH (WAGON) INPUT SIGNAL FOR
connector.
2) Turn trunk lid switch (or rear gate switch) ON/OFF and
measure voltage between security control module connec-
tor and body.
(Lid or gate closed)
/ 1 V, max.
(Lid or gate opened)
2. CHECK TRUNK LID SWITCH (SEDAN) OR REAR

GATE SWITCH (WAGON).
Refer to 6-2 [W8B2/W8B3] for inspection of trunk lid switch/
rear gate switch.
NOTE:
The trunk lid switch/rear gate switch is used for both trunk
room light/luggage room light.
94
DIAGNOSTICS 6-2
6. Security System
J: DIAGNOSTICS PROCEDURE FOR DOOR

LOCK/UNLOCK SWITCH SIGNAL
1. Check door lock/unlock switch input signal OK Go to next step on basic diagnostics procedure.
왘
for security control module. <Ref. to [K6D0].>
Not OK
왔
Not OK
2. Check door lock/unlock switch. 왘
Replace door lock/unlock switch.
OK
왔
Repair or replace wiring harness between door lock/
unlock switch and security control module.
1. CHECK DOOR LOCK/UNLOCK SWITCH INPUT

SIGNAL FOR SECURITY CONTROL MODULE.
connector.
2) Close all the doors and rear gate (WAGON), and lock
with ignition key.
nector and body.
NOTE:
When one of the door (driver, passenger or rear gate) lock
knobs is in unlocked position, the voltage may be 1 V, max.
4) Unlock the door with ignition key.
nector and body.
(B93) No. 1 — Body / 1 V, max.
2. CHECK DOOR LOCK/UNLOCK SWITCH.

Refer to 6-2 [W22B5] for inspection of door lock/unlock
switch.
95
6-2 DIAGNOSTICS
6. Security System
K: DIAGNOSTICS PROCEDURE FOR KEY

CYLINDER LOCK/UNLOCK SWITCH AND
TAMPER SWITCH SIGNAL
NOTE:
Key cylinder lock switch, key cylinder unlock switch and
tamper switch are combined as a unit.
1. Check key cylinder switch input signal for OK Go to next step on basic diagnostics procedure.
왘
security control module. <Ref. to [K6D0].>
Not OK
왔
2. Check key cylinder switch. Not OK Replace key cylinder switch.
왘
OK
왔
Repair or replace wiring harness between key
cylinder switch and security control module.
1. CHECK KEY CYLINDER SWITCH INPUT SIGNAL

connector.
nector and body while turning each key cylinder with igni-
tion key.
Doors (RH and LH), and rear gate (WAGON)
B6M0499A
(B93) No. 2 — Body / 1 V, max. (LOCK position)
/ 10 V, or more (other than
LOCK position)
(B93) No. 14 — Body / 1 V, max. (UNLOCK position)

UNLOCK position)
B6M0447A
96
DIAGNOSTICS 6-2
6. Security System
Trunk lid (SEDAN)

(B93) No. 15 — Body / 1 V, max.
(UNLOCK position)
UNLOCK position)
B6M0446A

nector and body while removing/installing key cylinder
switch from/to door outer handle.
(Switch is installed.)
/ 1 V, max.
(Switch is removed.)
NOTE:
B6M0409A
For SEDAN vehicles, remove key cylinder switch from
trunk lid key cylinder to perform the above inspection.
2. CHECK KEY CYLINDER SWITCH.

Refer to 6-2 [W22B4] for inspection of key cylinder lock/
unlock switch and tamper switch.
97
6-2 DIAGNOSTICS
6. Security System
L: DIAGNOSTICS PROCEDURE FOR

STARTER INTERRUPT SIGNAL
1. Check starter interrupt output signal for security OK 5. Check starter interrupt relay.
왘
control module.
OK Not OK
Not OK
왔 왔
Repair or replace Replace starter
wiring harness of interrupt relay.
starter motor circuit.
왔
Not OK
2. Check power supply for starter interrupt relay. 왘
Repair or replace wiring harness between starter
interrupt relay and battery.
OK
왔
Not OK
3. Check continuity of starter interrupt relay. 왘
Replace starter interrupt relay.
OK
왔
왘
Repair or replace wiring harness between starter
interrupt relay and security control module. interrupt relay and security control module.
OK
왔
Replace security control module.
1. CHECK STARTER INTERRUPT OUTPUT SIGNAL

connector.
nector and body.
3) Set security system in armed state.
B6M0445A
4) Open the door without ignition key to operate the secu-
rity system (alarm state).
5) Measure voltage between security control module and
body during alarm state.
(B93) No. 5 — Body / 1 V, max.
98
DIAGNOSTICS 6-2
6. Security System
2. CHECK POWER SUPPLY FOR STARTER

INTERRUPT RELAY.
1) Remove starter interrupt relay without disconnecting
connector.
2) Measure voltage between starter interrupt relay con-
nector and body.
B6M0506A
3. CHECK CONTINUITY OF STARTER INTERRUPT

RELAY.
1) Remove starter interrupt relay.
2) Check continuity between terminals No. 1 and No. 2 of
starter interrupt relay.
B6M0455

STARTER INTERRUPT RELAY AND SECURITY
CONTROL MODULE.
1) Disconnect connectors of starter interrupt relay and
starter interrupt relay and security control module.
(B59) No. 2 — (B93) No. 5 / 10 Ω, max.
B6M0500A
5. CHECK STARTER INTERRUPT RELAY.

Refer to 6-2 [W22B1] for inspection of starter interrupt
relay.
99
6-2 DIAGNOSTICS
6. Security System
M: DIAGNOSTICS PROCEDURE FOR HORN

ALARM SIGNAL
1. Check horn alarm output signal for security OK 5. Check horn relay.
왘
control module.
OK Not OK
Not OK
왔 왔
Repair or replace Replace horn relay.
wiring harness of horn
circuit.
왔
Not OK
2. Check power supply for horn relay. 왘
Repair or replace wiring harness between horn
relay and battery.
OK
왔
Not OK
3. Check continuity of horn relay. 왘
Replace horn relay.
OK
왔
4. Check harness connector between horn relay Not OK
왘
Repair or replace wiring harness between horn
and security control module. relay and security control module.
OK
왔
1. CHECK HORN ALARM OUTPUT SIGNAL FOR

connector.
nector and body.
B6M0461A
(B93) No. 13 — Body / repeats 1 V, max. (0.2 sec.)
and 10 V, or more (0.6 sec.)
intervals
100
DIAGNOSTICS 6-2
6. Security System
2. CHECK POWER SUPPLY FOR HORN RELAY.

2) Remove horn relay without disconnecting connector.
3) Measure voltage between horn relay connector and
body.
B6M0507A
3. CHECK CONTINUITY OF HORN RELAY.

1) Remove horn relay.
horn relay.
B6M0459
4. CHECK HARNESS CONNECTOR BETWEEN HORN

RELAY AND SECURITY CONTROL MODULE.
1) Disconnect connectors of horn relay and security con-
trol module.
2) Measure resistance of harness connector between horn
relay and security control module.
(B49) No. 1 — (B93) No. 13 / 10 Ω, max.
B6M0501A
5. CHECK HORN RELAY.

Refer to 6-2 [W15B2] for inspection of horn relay.
101
6-2 DIAGNOSTICS
6. Security System
N: DIAGNOSTICS PROCEDURE FOR

HEADLIGHT ALARM SIGNAL
1. Check headlight alarm output signal for security OK 5. Check headlight alarm relay.
왘
control module.
OK Not OK
Not OK
왔 왔
Repair or replace Replace headlight
wiring harness of alarm relay.
headlight circuit.
왔
Not OK
2. Check power supply for headlight alarm relay. 왘
Repair or replace wiring harness between
headlight alarm relay and battery.
OK
왔
Not OK
3. Check continuity of headlight alarm relay. 왘
Replace headlight alarm relay.
OK
왔
4. Check harness connector between headlight Not OK
왘
Repair or replace wiring harness between
alarm relay and security control module. headlight alarm relay and security control
module.
OK
왔
1. CHECK HEADLIGHT ALARM OUTPUT SIGNAL

connector.
nector and body.
B6M0457A
(B93) No. 12 — Body / repeats 1 V, max. (0.2 sec.)
and 10 V, or more (0.6 sec.)
intervals
102
DIAGNOSTICS 6-2
6. Security System
2. CHECK POWER SUPPLY FOR HEADLIGHT ALARM

RELAY.
1) Remove headlight alarm relay without disconnecting
connector.
2) Measure voltage between headlight alarm relay con-
nector and body.
B6M0508A
3. CHECK CONTINUITY OF HEADLIGHT ALARM

RELAY.
1) Remove headlight alarm relay.
headlight alarm relay.
B6M0455A

HEADLIGHT ALARM RELAY AND SECURITY
CONTROL MODULE.
1) Disconnect connectors of headlight alarm relay and
headlight alarm relay and security control module.
(B58) No. 2 — (B93) No. 12 / 10 Ω, max.
B6M0502A
5. CHECK HEADLIGHT ALARM RELAY.

Refer to 6-2 [W22B2] for inspection of headlight alarm
relay.
103

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6-1 SPECIFICATIONS AND SERVICE DATA

2) Disconnect connector and terminal from starter.

2) Load test (For reference)

2) Remove through-bolts from end frame.

3) Remove yoke from magnetic switch.

4) Remove screws securing end frame to brush holder.

5) Separate yoke from end frame.

6) Remove brush by lifting up positive (+) side brush

7) Remove armature from yoke.

8) Remove screws securing magnetic switch to housing.

9) Remove housing from magnetic switch.

10) Remove clutch from housing.

11) Take out steel ball from clutch.

12) Remove idle gear from housing.

13) Remove retainer and roller from housing.

14) Remove coil spring from magnetic switch.

3) Depth of segment mold

4) Armature short-circuit test

5) Armature ground test

4. BRUSH AND BRUSH HOLDER

3) Insulation resistance of brush holder

4) Brush spring force

2) Assembling magnetic switch, clutch, and housing

3) Installing armature to yoke

5) Installing end frame

2) Disconnect connector and terminal from generator.

3) Remove V-belt cover.

5) Installing end frame

2) Disconnect connector and terminal from generator.

3) Remove V-belt cover.

5) Remove bolts which install generator onto bracket.

6) Installation is in the reverse order of removal.

2) Remove the four through bolts. Then insert the tip of a

3) Hold rotor with a vise and remove pulley nut.

4) Remove rotor from front cover.

6) Remove bolt which secure battery terminal bolt, and

7) Separate diode plate from stator coil.

(3) Remove stator coil from diode plate.

8) Remove bolts which secure IC regulator, diode and

C: INSPECTION AND REPAIR

2) Slip ring outside diameter

1) Diodes on “+” side

2) Diodes on “−” side

2) Check operation as shown in chart below.

쐌 Before installing rear cover, insert pin from outside

쐌 When installing rear cover, heat portion 쎻

C: CLEANING AND REGAPPING

C: CLEANING AND REGAPPING

5. Spark Plug Cord

2) Disconnect connector from ignitor.

5. Spark Plug Cord

2) Disconnect connector from ignitor.

5. Spark Plug Cord

2) Disconnect connector from ignitor.

VB is less 12.5 V is less than or equal to VB, and

Combination Oil pressure warning light 12 V — 1.4 W

Front washer Pump type Centrifugal

Rear washer Pump type Centrifugal