Daihatsu Copen User Manual

SECTION I

i

SECTION 2

General information

Maintenance

Engine

Engine Mechanical

IntakeSystem

Exhaust System

LubricationSystem

Cooling System

Fuel System

EngineControl System

Emission Control System

Ignition System

Starting System / Charging System

Engine Mounting

Front suspension

Rear Suspension

Wheel & Tire

Drive Shaft / Propeller Shaft / Axle

Brake

Parking Brake

Brake Control

Clutch

ManualTransmission / ManualTransaxle

Steering

Power Steering

SRSAirbag System

Body

Exterior / Interior

Windshield Windowglass / Mirror

Door Lock & Theft Deterrent

Sunmof / T-Ber Roof /Convertible

- - -

Lighting

Wiper & Washer Meter

Audio & Visual System

Heater and Air Conditioner

Wiring Diagrams -A, B, C & D

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A1 GENERAL INFORMATION

	IMPORTANT SAFETY NOTICE------------	A1 - 1
	GENERAL DESCRIPTION---------------	A1 - 1
	WARNINGS, CAUTIONS AND	A1 - 1
	NOTES-------------------------------------
	GENERAL WARNINGS....................	A1 - 2
	HOW TO USE THIS MANUAL-------------	A1 - 3
	ARTICLES TO BE PREPARED---------	A1 - 3
	REMOVALAND INSTALLATION	A1 - 3
	PROCEDURES
	DESCRIPTIONOF SERVICE	Af - 4
	STANDARD VALUE
	CONTENTS NOT DESCRIBED IN	A1 - 5
	THIS MANUAL
	DEFINITIONS OF TERMS----------------	A1 - 5
	ABBREVlATlON CODES--------------------	A1		- 6
	HOW TO GRASP SPECIFIED
	TIGHTENING TORQUE FOR
	GENERAL STANDARD BOLT AND	A1 - 7
	NUT
	DETERMINING PROCEDURE FOR
	TIGHTENING TORQUE FOR
	GENERAL STANDARD BOLTS AND	A1 - 7
	NUTS
	UNIT	A1		- 9
	NEW UNIT BECAUSE OF THE	A1 - 9
	INTRODUCTION OF THE SI UNIT-----
	GENERAL SERVICE INSTRUCTION---	A1	-	10
	SUPPORTING POINTS FOR JACKS	A1	- 12
	AND SAFETY STANDS
	JACKING POINTS	A1	-	12
(.-	SUPPORTING POINTS OF SAFETY	A1 - 13
	STANDS
	SUPPORTING POINTS OF LIFTS-------	A1	- 14
	SWING ARM TYPE .......................	A1	-	14
	PLATE TYPE	A1	-	14
	TOWING INSTRUCTIONS----------------	A1 - 15
	TOWING WlTH ROPE( ONLY FOR	A1 - 15
	EMERGENCY )
	USING FLAT BED TRUCK--------------	A1	- 15
	WHEEL LIFT TYPE	A1	-	15
	DIAGNOSTICS INSTRUCTIONS---------	A1 - 16
	DIAGNOSIS	A1 - 16
	DATA LlNK CONNECTOR -----------------	A1 - 18
	DATA LlNK CONNECTOR	A1 - 18
	TERMINAL ARRANGEMENT ----------
	CONNECTION METHOD OF DATA	A1 - 18
	LINK CONNECTOR.......................
	CONNECTION METHOD OF EACH	A1 - 18
	SYSTEM .....................................
	INSTRUCTIONS FOR SYSTEM	A1 - 19
	lNSPECTlON ..................................

HANDLING INSTRUCTIONOF
CONNECTOR ..............................	A1 -19
CONNECTOR
REMOVAUINSTALLATION
PROCEDURE	A1 - 19
CHECK PROCEDURE OF WIRE
HARNESSAND CONNECTOR--------	A1 - 21
CIRCUIT INSPECTION OF
COMPUTER UNIT	A1 - 22
HANDLING INSTRUCTIONOF
SYSTEM .....................................	A1 - 23
INSTRUCTIONSFOR RADIO
INSTALLATION------------------------	A1	24
HANDLING INSTRUCTIONSON
CATALYTIC CONVERTER-EQUIPPED
VEHICLES	A1 - 24
PRECAUTION FOR VEHICLES
EQUIPPEDWlTH SRS AIRBAG AND
SEAT BELT PRETENSIONER	A1 - 25
INSTRUCTIONSFOR SERVICE
OPERATION	A1 - 25
VEHICLE IDENTIFICATION ---------------	A1 - 27
BODY COLOR CODE	A1	- 27
CHASSIS SERIAL NUMBER	A1	- 27
ENGINE TYPE AND ENGINE
NUMBER	A1 - 27
MANUFACTURER'SPLATE
POS~TION	A1 - 28

A1-1

1 IMPORTANT SAFETY NOTICE

1-1 GENERAL DESCRIPTION

1.The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is potentially hazard. However, one can handle it safely if he has the required knowledge.

2.Correct service methods and repair procedures are very vital for assuring not only the safety and reliability of a vehicle, but also the safety of service personnel concerned.

3.The methods and procedures contained in this manual describe in a general way the techniques which the manufacturer has recommended. Thus, they will contribute to ensuring the reliability of the products. The contents of the servicing operations come in a wide variety of ways. Moreover, techniques, tools and parts necessary for each operation are different widely from each other.

4.This manual does not cover all details of techniques, procedures, parts, tools and handling instructions which are necessary for these operations, for such coverage is impossible. Hence, any one who obtains this manual is expected first to make his responsible selection as to techniques, tools and parts which are necessary for servicing the vehicle concerned properly. Furthermore, he must assume responsibility for his actions in connection with his own safety.

S.Therefore, one should not perform any service if he is not capable of making responsible selection and/or if he can not understand the contents herein described, for this manual has been prepared for experienced service personnel.

, -.

i ~

1-2 WARNINGS, CAUTIONS AND NOTES

1.Allthese symbols have their specific purposes, respectively.

WARNING

rThis symbol means that there is the possibility of personal injury of the operator himself or the nearby workers if the operator fails to follow the operating procedure prescribedin this manual.

CAUTION

rThis symbol means that there is the possibility of damage to the component being repaired if the operator fails to follow the operating procedure prescribedin this manual.

NOTE
r To accomplish the operation in an efficient manner, additional instructionsconcerning the operation
are given in this section.	i I
	:,.-1 ,

-

!

A1-2

1-3 GENERAL WARNINGS

1-3-1 WARNING OVER THE WHOLE SERVICE OPERATIONS

1.Always wear safety glasses for eye protection.

2.Use safety stands whenever a procedure requires you to be under the vehicle.

3.Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.

4.Set the oarkina- brake when workina- on the vehicle.

5.0perate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.

6.Keep yourself and your clothing away from moving parts, when the engine is running, especially from the fan and belts.

7.To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

8.Do not smoke while working on a vehicle.

9.To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle.

10.Keep hands and other objects clear of the radiator fan blades! The electric cooling fan is mounted on the radiator and can start to operate anytime by a rise in coolant temperature or turning ON of the air conditioner switch in the case of vehicles equipped with an air conditioner. The electric cooling fan is also mounted on the condenser for air conditioner and starts to operate anytime when the air conditioner switch is turned ON. For this reason care should be taken to ensure that the electric cooling fan motor is completely disconnected when working under the hood.

2 HOW TO USE THIS MANUAL

2-1 ARTICLES TO BE PREPARED

When SST, tool, measuring instrument, a sort of fat and oil to be prepared before operation are necessary, those are described by compiling in the table as preparation tools at the beginning of each item.

However, the general tools, jacks, fixtures as considered being equipped aiways at the service shop are usually omitted.

2-2 REMOVAL AND INSTALLATION PROCEDURES

1.Block diagrams are posted so as to show the installed state of each part.

2.The application of a sort of fat and oil and sealer are instructed in the figure with arrow. And the indication of a tightening torque and non-reusable parts are also described. The explanation of each code is posted below the block diagram concerned.

3.The removal and installation (disassembling and assembling ) procedure list is shown just beneath of components figure.

The removal (disassembling) procedure, the installation (assembling) procedure and parts name are described in the sequence from left side of list. And the alphabet written before a part name links with alphabet in the figure.

4 . h principle, reverse the removal (or disassembly) procedure to install (or assemble) the parts.

NOTE

Only incases where the installation (or assembly) can not be carried out by reversingthe removal (or disassembly) procedure, the installation (or assembly) procedure is provided.

5 . h cases where a special procedure is required for the operation, a marking "VA"is provided in front of the removal (or disassembly) procedure. Furthermore, explanation is given in the "Main points of Removal (Disassembly)" or the "Main points of Installation (Assembly)."

The marking shows that there are the "Main points of Removal (Disassembly)." whereas "A" shows that there are the "Main points of lnstallation (Assembly).''

I

2-2-1 ENTRY EXAMPLE ) COMPONENTS

+ : Rubber grease

%: Non-reusable part Unit:Nm(kgf.cm]

(2) DISASSEMBLY AND ASSEMBLY PROCEDURES

1	a Cap, cylinder slide pin		8	h Plate, disc brake pad guide
2	b Pin, cylinder slide. No.1		9	i	Boot, cylinder
A 3	c Pad, disc brake, N o 2	r	10 j		Piston, disc brake
4	d Shim, anti squeal, No.1		11	k	Seal, piston
\.	e Pad, disc brake w/ indicator. No.?		12	1	Boot, pin
A 5
6	f Shim, anti squeal, No.1		13 rnPin, cylinder slide, No.1
7	g Plate, disc brake pad guide		14 n Bush, cylinder slide

2-3 DESCRIPTION OF SERVICE STANDARD VALUE

The necessary service standard value for inspection and service operation are described with bold letter in the text as standard and allowable limit. The details of terms are described in the section for definition of terms.

2-4 CONTENTS NOT DESCRIBED IN THIS MANUAL

The description of the next elemental operation may omit in this service manual, but please perform in an actual operation.

1.Jacking operation and lifting operation

2.Cleaning and cleansing of removed parts to perform at need 3.Visual inspection

2-5 DEFINITIONS OF TERMS

VALUE

I	L t W t , 4
	DEVIATION

This mark shows the standard value a! the time of the check or adjustment.

This mark shows the maximum or minimum value at the time of the check or adjustment.

I

Th~svaLe refersto lne d~flerencebe!ween tne maxlmm clearance ano the m i n i m ~clearance~.

t

3 ABBREVIATION CODES

The abbreviation codes that appear in this manual stand for the following, respectively.

IABBREVIATION CODE I

ORIGINAL WORD

IABBREVIATION CODE I

ORIGINAL WORD

I

FR	Front	W/	With
GND	Ground	WVTA	Whole Vehicle Type Approval
HC	Hydro Carbon	@	Bolt
IG	Ignition	0	Screw
IN	Intake	0	Nut
ISC	Idle Speed Control	@	Washer
LED	Light Emitting Diode	0	Clip

4 HOW TO GRASP SPECIFIED TIGHTENING TORQUE FOR GENERAL STANDARD BOLT AND NUT

4-1 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS AND NUTS

4-1-1 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR BOLTS

Determine the strength division of bolts, based on the table below. Then, obtain the value, based on the tightening torque table.

4-1-2 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR NUTS

Determine with the aforesaid method, based on the mating bolt.

4-1-3 IDENTIFICATION

Identificationof strenglh division by checkhg bolts themselves

Classification		Shape of head (how to know strength division)
(Strength division)		Bolt without collar	Bolt with collar
4	T	@	@
		0	0
5	T	@	-
		0

Identificationby part number

Hexagonalbolt

Exampleofpartnumber9 1 1 1 1 - 4 0 6 2 0

,saGqJJJ

Nominaldiameter (mm)

Nominal length (mm)

f Nominal diameter

t----i

Nominallength

4-1-4 TIGHTENING TORQUE TABLE FOR GENERAL STANDARD BOLTS

	Strength divisin	Nominal diameter	Pitch	Standard tightening torque		(N.rn(kgf.cm))
		(mm)	(mm)	Bolt without collar	1	Bolt with collar
		6	1.O	5.4 (55)	I	5.9 160)

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5 UNlT

As for the units, the SI units (international unit system) have been posted. (The hitherto-employed units, too, are posted.)

Example: 33.25k 13.25N-m{340_f135kgf.cmJ

5-1 NEW UNlT BECAUSE OF THE INTRODUCTION OF THE SI UNlT

1.SI unit is the international unit system established by aiming to proceed the communication in technology smoothly by unifying the former unit system which were different internationally each other into one value by one unit. The specification value is described in accordance with SI unit system in this service manual.

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6 GENERAL SERVICE INSTRUCTION

1.Use fender covers, seat covers, and floor sheets so that the vehicle may not get dirty or be scratched.

2.Jacking up

(1)When only front section or rear section of a vehicle is jacked up, be sure to place chocks at the wheels so as to insure safe operations.

(2)When the vehicle has been jacked up, be sure to support the vehicle at the specified section using the safety stands.

(3)When the vehicle has been lifted up, be sure to set the cradle of the lift at the specified location,

and lift it up. And after the jacking up, ensure to apply the protective safety device. And after the jacking up, ensure to apply the protective safety device.

(4) The jack-up operation must be carried out only on a level, flat place.

(5) Never jack up the vehicle at the front and rear sides at the same time. 3.lnstallation and removal of battery terminal

(1)Before you start performing the electrical works, make certain to disconnect the battery ground cable terminal from the negative terminal of the battery.

(2)Before disconnecting the battery ground cable terminal from the negative terminal of the battery, be sure to read out the diagnosis code of the EFI systems if it is equipped.

(3)After reconnecting the battery ground cable terminal to the negative terminal of the battery, be sure to reset the watch or radio, if the vehicle is equipped with such equipment.

(4)When it becomes necessary to disconnect the battery power supply for the purpose of carrying out checks or repairs, always disconnect the negative terminal of the battery ground cable from the negative terminal of the battery first.

(5)To avoid damaging battery plates, after the terminal nut has been loosened, pull out the battery ground cable terminal straight upward, rather than turning or prying the terminal.

(6)Be sure to employ a battery terminal puller (commercially available) to remove battery ground cable terminal from the negative terminal of the battery, if any difficulty is encountered.

(7)Clean the battery terminal posts or battery ground cable terminals, using a cloth. Never use a file or other abrasive agents.

(8)Install the battery cable terminals to the battery posts after loosing the nuts, and tighten the nuts after installation. Never tap the terminals on the battery posts using a hammer or the like.

(9)As for the cover at the positive (+) terminal side, be sure to install it at the correct position. 4.Repairing of fuel system

(1)Do not work near open flames.

(2)Be certain to place a suitable container, a cloth, etc. under the connected section of the fuel line before disconnecting the fuel line.

(3)Before the fuel line is disconnected, be sure to release the inner pressure of the fuel tank by detaching the fuel filler cap.

(4)Be sure to prevent the fuel from splashing with a cloth or the like, when the union bolt or other connected section of the fuel line is loosened or slackened.

(5)Tighten each connecting section to the specified torque.

(6)Attach the specified clips to each connecting section.

5.For increased work efficiency and improved accuracy, be sure to utilize the SSTs (Special Service Tools) effectively.

6.Removal, Disassembly

(1)In case for the operation at the complicate place, the stamping and mating mark shall be put at the place where there is no influenceto the function, so that the assembling operation becomes easy.

(2)At every time when each parts are removed, check the condition when it was assembled , deformation, breakage, roughness and existence of scratch .

(3)Arrange the removed parts in order, and divide them to the parts to replace and parts to reuse .

(4)Each parts to be reused shall be performed enough cleaning and cleansing operation.

7.Check and measurement of parts

(1) As regards those parts to be used again, perform thorough checks and measurements, as required.

8.lnstallation. Assembling

(1)Assemble the good parts with correct procedure following the specified standard (value for the adjusting , tightening torque).

(2)Use the genuine parts when replacethe parts.

(3)Ensure to apply the seal packing and grease by a place.

(4)Ensureto use new packing, gasket or the like, cotter pin etc.

(5)When use the seal bolt, apply the specified liquid gasket and seal lock agent on.

(6)As for bolts and nuts, use the specified ones. Unless otherwise specified, the side for which the torque is indicated should be tightened to the specified torque, using a torque wrench. If there

is no means to prevent the turning at the opposite side, be sure to prevent turning with box wrenches, spanners or the like.

S.Adjustment, Operation confirmation

(1) Adjust with the specified service standard value by using the gauge and the tester. 10.Handlingof hose or the like

(1)Ensureto insert the fuel hose, water hose or the like without coming out or leakage.

(2)Be careful that fuel shall not splash on the parts near by when remove the fuel hose. (Deep care shall be paid for engine mount rubber or the like, as there may be possibility to get material

deterioration for liquid of gasoline series.) 11.Touch up

(1)When removed the bolt or the like during body fitting operation and others, the scratch of the paint finishing surface on the body and bolt shall be repaired by the body color.

7 SUPPORTING POINTS FOR JACKS AND SAFETY STANDS

7-1 JACKING POINTS

CAUTION

= Be sure to set the jack in such a way that jack may not interfere with the bumper. Never apply a jack to the rear suspension intermediatebeam section.

Failure to observe this instruction may hamper the controllability due to beam deformation or breakage.

Jacking points

Front side: Central projection at the front of the front frame ?earside: Transport hook section

@ :Jacking point

7-2 SUPPORTING POINTS OF SAFETY 'STANDS

CAUTION

Never support the vehicle at points other than the specified points.

a:Safetystand support

8 SUPPORTING POINTS OF LIFTS

8-1 SWING ARM TYPE

Supporting points of lifts: Safety stands supporting point

asupporting points of lifts

I C13S5503ESZC

8-2 PLATE TYPE

Supporting points of lifts:

Drive the vehicle onto the center of the supporting platforms both at the right and left.

.Since the vehicle is heavier at the front than the rear, lift up the vehicle at the front wherever possible.

7

m:Supporting pointsof lifts

9 TOWING INSTRUCTIONS

t

1.Be certain to transfer the vehrcle by usmg the flat deck truck when the running system andlor driving system seems to be abnormal.

9-1 TOWING WITH ROPE( ONLY FOR	I Towing with rope	1
EMERGENCY )

Release parking brake, and turn IG switch to ACC position, and then put the sift lever into neutral range.

9-2 USING FLAT BED TRUCK	I Using flat bed type	I
1.Transfer the vehicle with applying parking brake and
fixing the vehicle firmly.

9-3 WHEEL LIFT TYPE

CAUTION

Do not allow anyone to be in the vehicle being towed.

9-3-1 TO TOW WlTH REAR WHEELS ON GROUND

1.Release the parking brake.

9-3-2TO TOW WlTH FRONT WHEELS ON GROUND

1.Use a towing dolly.

2.lf a towing dolly is not available, and turn IG switch to ACC position, and then put the sift lever into neutral range (for manual transmission vehicle).

10 DIAGNOSTICS INSTRUCTIONS

10-1DIAGNOSIS

10-1-1 HOW TO PROCEED DIAGNOSIS

1 Each electronic control system equipped on the vehicle is an important clue at performing trouble shooting. Also this system has self-diagnosis function to inspect the malfunction portion which occurred in corresponding system, and battery back up (the function that power source for diagnosis code memory is supplied even if IG switch is OFF) is equipped for self-diagnosis function of electronic control system with, and is designed so that diagnosis code is memorized to each system. As the function of diagnosis code memory is different by each system, perform the confirmation / elimination of code memory according to the right operation procedure after confirming equipped diagnosis code memory function.

(Entry of malfunctioningvehicle)

1

Diaanosis throuoh auestion-and-answer

I-------------- ----I

Ask the customer concerning

the conditions and the environment when maifunctionoccurred.

t

onfirmation and record of diagnosis cod
Erasure
	i
of diagnosis code
(~econfirmationof malfunctioningphenomenon)--		. .... I
Reconfirmation
	of diagnosis code
Abnormal code	1 Normal code
I	1	--{

Conlirm phenomenonand qrasp problemcono~tions.

Narrow down malfunctioningsystems. /

t

rouble-shooting according)
\	to diagnosis code	,)
	I	f~rouble-shootinaaccordino\
	1	( malfunctioning&enomen&		)
	Repair or replace
Confirmationtest (Has+vehicle resumed its normal operation?)				Confirmthat the malfunctioning
				phenomenonthat customer spoke
				about has been remedied completely.
	c eYES )		)------'-

10-1-2 SYMPTOM CONFIRMATION

1.When conducting a trouble shooting, the operator cannot pinpoint the cause for the malfunction, unless he actually confirms the phenomenon. For this purpose, it is indispensable to reproduce the malfunctioning phenomenon by creating conditions and environments that are similar to those where the malfunction actually took place, based on the information obtained through the inquiry with the customer. As for phenomena which cannot be reproduced easily, it is necessary to produce running conditions that are close to those when the malfunction took place (road surface condition, weather condition, and driving condition), based on the information obtained through the inquiry with the customer. To this end, it is of great importance to try to reproduce the malfunction persistently by applying external factors, such as vibration (moving wire harnesses and relays by hand), heat (applying hot air), and water (applying moisture). Furthermore, while the malfunction phenomenon is being reproduced, it is essential to check diagnosis codes indicated before and after the confirmation of the malfunction phenomenon. Checking whether the code that was indicated before the confirmation is outputted or not is also an important step for confirming the malfunction phenomenon.

10-1-3 CUSTOMER PROBLEM ANALYSIS

!

1.For the vehicle which malfunctions occurred, confirm first the malfunction phenomenon, and study the cause and then eliminate the cause. There is possibility that the vehicle does not return to normal condition even if perform many operation without study of cause. An asking about problems is to gather the information from the customer before confirming the malfunction phenomenon, and become an important clue when attempt to reproduce the malfunction. When perform the asking about problem, it is necessary to focus to the items relating to said malfunctions so that information attained with an asking about problems becomes useful reference of trouble shooting.

11 DATA LlNK CONNECTOR

11-1 DATA LlNK CONNECTOR TERMINAL ARRANGEMENT

No	Terminal code	No	Terminal code
@I	BAT(DS-21)	@	ITC-T
0	-	@	SIO(DS-21)
0	-	0	-
@	ECU-T	0	E( Signal earth)
8	EFI-1	0	E( Body earth)
8	W (immobilizer)	@	-
			-
0	-	0
@	REV	@	VF	I

11-2 CONNECTION METHOD OF DATA LlNK CONNECTOR

Perform it by connecting the engine control system inspection wire (SST) with the data link connector. Perform the system check of each system by using the terminal for Connect circuit (SST), the terminal for detecting engine speed and the terminal for VF output monitoring (SST)

11-3 CONNECTION METHOD OF EACH SYSTEM

1.Diagnosis code output of engine control system :Connect circuit between EFI-T - E

2,Functioning check of O2sensor for engine control system : Measure between VF -E

3.Engine speed check of engine control system

:Measure between REV - Body earth 4.Diagnosis code output of ABS system

:Connect circuit between ECU-T - E 5.Diagnosis code output of SRS airbag system

:Connect circuit between ECU-T - E 6.Diagnosis code output of immobilizer system

: Connect circuit between ECU-T - E, SST between BAT(DS-21) -W(lmmobiiizer) 7.0peration check of body integrated controller and hazard lamp system

: Connect circuit between ITC-T - E

8.Diagnosis code output of electric openinglclosing roof system : Connect circuit between ECU-T - E

12 INSTRUCTIONS FOR SYSTEM INSPECTION

12-1 HANDLING INSTRUCTION OF CONNECTOR

1.Connection or disconnection of the connector and each terminal shall be performed basically after the removal of negative termrnal of the battery.

However, there may be the case that diagnosis code is erased when remove the negative terminal of battery, so confirm the diagnosis code first before the removal of battery negative terminal when need to confirm.

2.When disconnecting connectors, be sure to hold the connector itself with the connector unlocked.

Never pull harnesses. When connecting connectors, be sure to positively insert the connectors, until you hear a clicking sound and the lock is engaged.

3.When inserting tester probes into a connector, insert them from the rear side of the connector.

4.For water-proof connectors which cannot be accessed from behind, take good care not to deform the connector terminals.

5.Never touch the terminal of connector directly by hand. 6.When a tester probe is applied to a terminal to which

voltage is applied, care must be exercised so that two tester probes may not come in contact with each other so that short circuit may not take place.

12-2CONNECTOR REMOVALANSTALLATION PROCEDURE

12-2-1 CONNECTOR WITH LOCKING BUTTON

(1) Type 1

@ POINTS OF REMOVAL

1.lnsert a flat screwdriver with a thin forward end (approx. 2 mm wide) into the locking button at the point A. Raise the locking button, utilizing lever principle, until you hear a clicking sound, thus unlocking the connector.

LDOnot insert the tester probe in place.- -

GO7E5024EnO

-

S1BC5012ETlO

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A1-20

2.lnsert a flat screwdriver with a thin forward end (approx. 2 mm wide) at the point B or C. Pry the point with the screwdriver in the arrow direction, utilizing lever principle, thus removing the connector.

@ POINTS OF INSTALLATION	Locking button
1.lnsert the connector firmly as far as it goes. Push and	I
lock the connector, until the locking button clicks.

I

(2)Type 2

@POINTS OF REMOVAL

1.With a flat screwdriver with a thin forward end, pull out the locking button in the arrow direction, thus unlocking the lock. Then, remove the connector.

@ POINTS OF INSTALLATION

1.lnsert the connector firmly as far as it goes. Push and lock the connector, until the locking button clicks.

12-2-2 CONNECTOR WITH LEVER LOCK

(1) POINTS OF REMOVAL

1.Push the lock of the lever section in the arrow direction, thus unlockingthe lock.

2.Turn the lever about 40"in the direction A. Then, apply force in the direction B to turn the lever.

3.Ensure that the lever has been turned fully. Then, remove the connector,

(2) POINTS OF INSTALLATION

1.lnsert the connector to the mating side. Turn tkle lever in the direction A to lock the connector.

L

12-3CHECK PROCEDURE OF WIRE HARNESS AND CONNECTOR

	Perform the inspection of wire harness and connector portion in the distinctive system inspection in
	accordance with next points.
	12-3-1 CONTINUITY INSPECTION	Sensor side	Computer side
	1.Remove the connector of corresponding harness on both
	ends.
	2.Measure the electrical resistance between corresponding
	terminals of connector on both end.
	SPECIFIED VALUE: Not more than 1Q
	CAUTION
	r Measurethe electrical resistance while shaking wire
	harness in top and down and right and left lightly.
	NOTE
	0 In case of open circuit, as it is seldom that open circuit
	happen in central part of wiring harness, and most of
	part the open circuit happen are connector area.
	Particularly, check the connector of the sensor portion
	carefully.
	12-3-2 SHORT CIRCUIT INSPECTION	Sensor side	Computer side
	1.Remove the connector of corresponding harness on both

end.

2.Measure the electrical resistance between corresponding terminal of connector and body earth connecting. In addition to above, perform the inspection with the connector of each side.

SPECIFIED VALUE: Not less than I M Q CAUTION

r Measurethe electrical resistance while shaking wire harness in lop and down, and right and left lightly.

A1-22

3.Measure electrical resistance between terminals in same connector with the connector of COrreSpondin~- terminal (except between each power supply lines or earth lines). In addition to above, perform the inspection at the connector of both sides.

SPECIFIED VALUE: Not less than 1MQ CAUTION

There may be short circuits due to wiring in the vehicle compartment which is pinched by the body or faulty clamps.

12-3-3 VISUAL INSPECTION, CONTACT FORCE INSPECTION

1.Remove the connector of corresponding harness on both end.

2.Check visually the rust generation or mixing of the foreign material at connector terminal portion.

3.Check whether there are looseness, damage at the staking portion and check coming out from the coupler by pulling the wire harness lightly.

4.Prepare the same male terminal as that of the connector terminal. Insert it into the female terminal and check the pulling force.

The terminal having a smaller pulling force, compared with other terminals, may cause poor contact.

CAUTION

r If the terminal section has rust formation, admission of foreign matters or poor contact pressure betweenthe male terminal and the female terminal, the contact condition may change by disconnecting and reconnectingthe connector once, thus resulting in No malfunction.

Therefore, if the check of the wire harness and connector revealsthat there is no malfunction, confirm the malfunction phenomenon. At this time, if no malfunction phenomenon is reproduced, most likely the poor contact betweenthe male terminal and the female terminal was causing the malfunction.

12-4 CIRCUIT INSPECTION OF COMPUTER UNIT

Perform computer unit circuit inspection. If it is malfunction, repair the corresponding connector, circuit, and if normal, change the computer unit.

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I.VISUAL CHECK OF CONNECTOR PORTION, CONTACT FORCE INSPECTION

Check the connector of computer unit according to visual check and the contact force check point described in former page.

2.COMPUTER UNIT EARTH CONNECTING INSPECTION

Remove the connector of computer unit, and then measure the applied voltage between each power source terminal, each earth connector and body earth connecting.

SPECIFIED VALUE: VOLTAGE OF EACH POWER SUPPLY TERMINAL

CAUTION

0At the computer unit circuit check, there may be cases when the malfunction disappears by removing and installingthe connectors, due to change of contact condition. Accordingly, when the result of computer unit circuit check is normal, judge that computer unit is malfunctionedafter confirmingthe malfunction again by connectingthe computer unit connector.

12-5 HANDLING INSTRUCTIONOF SYSTEM

1.The computer unit, sensors, etc. are precision parts. Be very careful not to give strong impacts to	t,
those parts during the installation and removal. Never use those parts which impacts have been
given (for example, in case where the parts were dropped on the floor).
2.When the test is carried out on rainy day or the vehicle is washed, care must be exercised so that no
water may be admitted and the computer unit, connectors, sensors, actuators, etc. may not get wet.
3.ln cases where the computer unit was judged to be malfunctioning and the vehicle has been
remedied by replacing it, install the removed computer unit (which has been judged to be
malfunctioning) again to confirm that the original malfunction is reproduced. Then the computer unit
can be finally judged to have been malfunctioning.

1

13 INSTRUCTIONS FOR RADIO INSTALLATION

CAUTION

For those motor vehicles equipped with a mobile communication system, such as a bidirectional wireless telephone and cellular phone, be sure to observe the following precautionary measures

l.lnstal1 the antenna as far away as possible from electronic control system.

2.As the electromagnetic wave is radiated from antenna feeder, set the antenna feeder within the distance at least not less than 300 mm apart from computer unit and ECU harness. Do not arrange both line in parallel for long distance.

3.Never bind the antenna feeder together with the engine harness with binding tape. 4.Regulatethe antenna and the feeder to get rid of radio interference.

5.Never install a strong mobile communication system (exceeding 10 kW).

14 HANDLING INSTRUCTIONS ON CATALYTIC CONVERTEREQUIPPED VEHICLES

1.Use only unleaded gasoline to catalytic converter-equipped vehicles.

2.Utmost care must be paid as to the following points, for the catalyst will be damaged if a large amount of unburned gasoline flows into the catalytic converter.

(1)Do not operate the engine with the fuel in the fuel tank almost empty.

(2)The spark jump test must be limited to cases where such test is absolutely necessary. Also, be sure to finish the test in the shortest possible time.

(3)The spark check of the spark plug and engine compression pressure measurement must be performed with the fuel pump relay and injector connector disconnected and fuel injection

stopped.

3.Do not dispose the waste catalyst along with parts contaminated with gasoline or oil.

15 PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER

15-1INSTRUCTIONS FOR SERVICE OPERATION

Be sure to perform the service operation for the vehicle equipped with the airbag and seat belt pretensioner according to the correct procedure and method, otherwise, the airbag or pretensioner may occur the malfunction and lead serious accidents during the service operation.Be sure to perform the service operation according to the correct procedure and method described in this manual.

15-1-1 PRECAUTION PRIOR TO SERVICE OPERATION

1.Before servicing the airbag components or the seat belt pretensioner device, perform the following procedures.

(1) Check the status of airbag warning lamp.

(2) Read the diagnosis codes and put it on record

(3) .Turn OFFthe ignition switch and detach the negativeterminal of the battery cable.

(4) Then, wait for at least 60 seconds to prevent the airbag from the deployment. WARNING

* If the operation is started within 60 seconds from disconnecting the negative terminal of the battery

i,

cable, the airbag may be deployed.

NOTE

As airbag system providethe back up capacitor (for ignition purpose), about 60 seconds is necessary as discharging time even though the battery negativeterminal cable is disconnected. (natural discharge)

CAUTION

*Be careful that memory of computer of other system (such as engine control) may be erased simultaneously when the battery negative terminal cable is disconnected.

2.Ensure to use the digital circuit tester for the electric inspection of the vehicle equipped with the a~rbag,pretensioner, and use the circuit tester which satisfy the following standard.

WARNING

0Ensure beforehandto measure the electric current value of circuit tester to be used for an operation, and confirm if it satisfy the following specified value. When the circuit tester exceeding

specified value is used, there may be possibility that malfunction or deterioration of alrbag occur. In addition to above, measure the electric current of the circuit tester with minimal resistance ( Q ) range.

SPECIFIED VALUE: Not more than 50 mA (0.05A)

15-1-2 PRECAUTIONTO PREVENT MISS OPERATION

1.Be sure not to drop the airbag system component parts during removal and installation. 2.Be sure not to give impact or damage when removing the airbag system component parts.

3.Be sure to put the pad Ay and assistant driver'sseat airbag unit with deployment surface upward during the operation though it is temporary operations. And never stack the pad Ay. (It may lead to serious accidents if metal surface is facing upward at an emergency)

4.Keep the airbag system component parts in the place where the effect of electricity noise, the high-temperature (not less than atmosphere temperature 85"C), and high humidity can be avoided.

5.Do not expose the airbag system component parts directly to high-temperature or flames. 6.Considering the case an airbag is actuated at an emergency, perform the service operation with

posture as not to get your body close to deploying portion as much as possible.

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15-75 GENERAL SERVICE INSTRUCTION

1.Follow the indication of the caution plate affixed on the airbag system related parts. 2.Be sure to mate the center when the steering roll connector is installed.

3.Be sure to perform the mating of the center for steering roll connector and marking to the separating portion when repair the related parts described beiow.lf the relation of mutual position of parts are changed, the harness of roll connector may be snapped when the steering wheel is operated.

(1) STEERING CONCERNED

1.Steeringwheel, steering column, steering gear or the like

(2) VEHICLE BODY CONCERNED

1.Instrument panel or the like 2.Body electrical malfunctioned 3.Multi-use lever switch or the like

(3) POWER TRAIN CONCERNED

1.The case when separate the connection of steering gear at the removal and installation of the engine and transmission and so on.

15-1-4 PRECAUTION PRIOR TO BODY AND PAINT OPERATION

1.As an inflator or the like are installed in the steering wheel central part, the upper part of instrument panel, the root of B pillar. Be sure not to give strong impact with hammer or the like, and high temperature during repairing.

2.Perform the operation after removing airbag system component parts when use of electric welding machine is needed.

3.Perform the operation after removing the airbag system component parts when use of impact and the high temperature is needed.

4.Do not expose the painting surface near the airbag related parts to high temperature ( 85°C or more) during drying it.

5.Be sure to change with new parts when an airbag related parts have the external scratch, deformation.

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16 VEHICLE IDENTIFICATION
16-1BODY COLOR CODE
Body color name	Color code
Silver metalic	S28
Red	R40
White	056
Dark blue mica melalic	842
Sunflower yellow	YO7
Dark green mica	6Q7
Black mica	NO5
Pearl white	W16

16-2 CHASSIS SERIAL NUMBER

1.The chassis serial number is stamped on the position as shown in the illustration.

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16-3 ENGINE TYPE AND ENGINE NUMBER

1.The engine type and engine number are given on the places as shown in the illustration.