1kr fe starting starting motor

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ENTRY AND START SYSTEM > PARTS LOCATION

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ENTRY AND START SYSTEM > SYSTEM DIAGRAM

Communication table: Sender Receiver Signal LineECM Main body ECU Engine rotation signal CAN

Meter ECU Main body ECU Vehicle speed signal CANSteering lock ECU Main body ECU Steering lock/unlock signal LIN Certification ECU Main body ECU LIN master signal LIN Main body ECU ID code box ID required signal LIN Main body ECU Certification ECU Key existence condition signal LIN

ENTRY AND START SYSTEM >

SYSTEM DESCRIPTION ENTRY AND START DESCRIPTION

1. The entry and start uses a push-type ignition switch, which the driver can operate by merely carrying the key. This system consists primarily of the main body ECU, ignition switch, ID code box, steering lock ECU, key, ACC CUT relay, IG1 relay, IG2 relay and certification ECU. The main body ECU controls the system. This function operates in cooperation with the entry and start system. The table below shows the transition of the ignition switch, which depends on whether the clutch pedal is depressed or released.

2. This system has different power source mode patterns depending on the clutch pedal conditions.

For M/T: Clutch Pedal Power Source Mode Pattern

Not depressed

Each time ignition switch is pushed

• off → on (ACC) → on (IG) → off

Not depressed

When ignition switch is pushed in the engine started condition

• Engine started → off

Depressed

When ignition switch is pushed once

• off → engine start

Depressed

When ignition switch is pushed in the on (ACC) condition

• on (ACC) → engine start

Depressed When ignition switch is pushed in the on (IG) condition

• on (IG) → engine start

Depressed

When ignition switch is pushed in the engine started condition

• Engine started → off

For except M/T: Brake Pedal Shift Lever Power Source Mode Pattern

Depressed N Position

7. When the engine switch is pushed once. • OFF → IG ON (after the

engine is started)

N Position

8. Each time the engine switch is pushed. • OFF → ACC → IG ON →

OFF Not Depressed

Except N Position

9. Each time the engine switch is pushed. • OFF → ACC → IG ON →

OFF

- N Position

10. When the engine switch is pushed in the IG-ON condition.

• IG ON (engine is started or not started) → OFF

- Except N Position

11. When the engine switch is pushed in the IG-ON condition.

• IG ON (engine is started or not started) → OFF

When the battery of the key is low, the entry and start function can be operated by holding the key against the ignition switch.

FUNCTION OF COMPONENT

Components Function

Ignition Switch (Transponder Key

Amplifier)

• Transmits ignition switch signal to main body ECU. • Informs driver of power source mode or system

abnormality with indicator light illumination. • Receives ID code and transmits it to certification ECU

when battery of key is low.

Key • Receives signals from oscillators and returns ID code to

entry door control receiver.

Indoor Electrical Key Oscillator

(Front and Rear)

• Receives request signal from certification ECU and forms detection area in vehicle interior.

Entry Door Control Receiver

• Receives ID code from key and transmits it to certification ECU.

Main Body ECU

• Changes power source mode in 4 stages (off, on (ACC), on (IG), start) in accordance with state of clutch start switch or park/neutral start switch.

• Controls entry and start function in accordance with signals received from switches and each ECU.

Certification ECU

• Certifies ID code received from entry door control receiver and transmits certification results to ID code box and steering lock ECU.

Stop Light Switch • Outputs state of brake pedal to main body ECU.

Clutch Start Switch (M/T)

• Outputs state of clutch pedal to main body ECU.

ID Code Box

• Receives steering unlock or engine immobiliser unset signals from certification ECU, certifies them, and transmits each unset signal to steering lock ECU or ECM.

ECM

• Receives engine start request signal from power source control ECU, turns ON ST relay, and starts engine.

• Receives signal from immobiliser code ECU and performs engine ignition and injection.

SYSTEM FUNCTION The electric controls of the entry and start function are described below:

Control Outline

Ignition Switch Control

• When driver operates ignition switch with key in driver's possession, certification ECU starts indoor electrical key oscillator, which transmits request signal to key. Upon receiving this signal, key transmits ID code signal to main body ECU.

• ID code box verifies check results received from certification ECU via LIN and sends them to main body ECU. Based on these results, main body ECU authorizes operation of ignition switch.

Diagnosis • When main body ECU detects malfunction, main body ECU

diagnoses and memorizes failed section.

CONSTRUCTION AND OPERATION

1. Ignition Switch Ignition switch consists of a momentary type switch, 3 color (amber, green, greenish white) LEDs, and transponder key amplifier.

• The greenish white LED is for illumination. • The amber and green LEDs are for the indicator lights. The driver can

check the present power source mode and whether the engine can start or not in accordance with the illumination state of the indicator light.

• When the main body ECU detects an abnormality in the entry and start system, it makes the amber indicator light flash. If the engine stopped in this state, it might not be possible to restart it.

2. Indicator Light Condition

Ignition switch indicator light condition Indicator Light Condition

Power Source Mode/Condition

Clutch pedal released (M/T)

Brake pedal released (except M/T)

Clutch pedal depressed (M/T)

Brake pedal depressed (except M/T)

Off OFF Illuminates (Green) On (ACC, IG) Illuminates (Amber) Illuminates (Green) Engine running OFF OFF

Steering lock not unlocked Flashes (Green) for 15 seconds

Flashes (Green) for 15 seconds

System malfunction Flashes (Amber) for 15 seconds

Flashes (Amber) for 15 seconds

Clutch switch malfunction (M/T)



3. Main Body ECU The main body ECU consists of the IG1 and IG2 relay actuation circuits and CPU.

WHEN KEY BATTERY IS LOW

1. To operate the entry and start function when the key battery is low, hold the TOYOTA mark of the key against the ignition switch while depressing the brake pedal.

2. The main body ECU transmits a key verification request signal from the stop light switch to the certification ECU.

3. The certification ECU does not receive an ID code response from the smart tuner, so it actuates the transponder key amplifier built into the ignition switch.

4. The transponder key amplifier outputs an engine immobiliser radio wave to the key.

5. The key receives the radio wave, and returns a radio wave response to the transponder key amplifier.

6. The transponder key amplifier combines the key ID codes with the radio wave response, and transmits it to the certification ECU.

7. The certification ECU judges and verifies the ID code, and transmits a key verification OK signal to the main body ECU. The buzzer in the combination meter sounds at the same time.

8. After the buzzer sounds, if the ignition switch is pressed within 5 seconds with the brake pedal not depressed, the power source mode changes to on (ACC) or on (IG), the same as in the normal condition.

DIAGNOSIS The main body ECU can detect malfunctions in the entry and start function when the power source mode is on (IG). When the ECU detects a malfunction, the amber indicator light of the ignition switch flashes to warn the driver. At the same time, the ECU stores the 5-digit DTC (Diagnostic Trouble Code) in the memory.

• The indicator light warning continues for 15 seconds even after the power source mode is changed to off.

• The DTC can be read by connecting the intelligent tester to the DLC3. • The entry and start function cannot be operated if a malfunction occurs.

ENTRY AND START SYSTEM > HOW TO PROCEED WITH TROUBLESHOOTING HINT:

• Use these procedures to troubleshoot the push-button start function. • *: Use the intelligent tester.

1.VEHICLE BROUGHT TO WORKSHOP NEXT 2.INSPECT BATTERY VOLTAGE

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

NEXT 3.INSPECT COMMUNICATION FUNCTION OF LIN COMMUNICATION SYSTEM*

1. Using the intelligent tester, check if the LIN Communication System is functioning normally ().

Result

Result Proceed to DTC is not output A

DTC is output B

B. GO TO DIAGNOSTIC TROUBLE CODE C A 4.CHECK FOR DTC*

1. Check for DTCs and note down any stored DTCs ( ).

2. Delete the DTC.

3. (c) Check whether the same DTC(s), relevant to the SFI or entry and start systems, recurs by reproducing the symptoms indicated by the noted DTC(s) in step (a) above.

Result

Result Proceed to

DTC output does not reoccur A

SFI system (1KR-FE) DTC output reoccurs B

Entry and start system DTC output reoccurs C

B. GO TO SFI SYSTEM (1KR-FE)

C. GO TO STEP 7 A 5.PROBLEM SYMPTOMS TABLE

Result Result Proceed to

Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B

B. GO TO STEP 7 A 6.OVERALL ANALYSIS AND TROUBLESHOOTING*

1. Terminals of ECU ()

2. Data List/Active Test ()

NEXT 7.ADJUST, REPAIR OR REPLACE NEXT 8.CONFIRMATION TEST NEXT

END

ENTRY AND START SYSTEM > PROBLEM SYMPTOMS TABLE HINT:

Use the table below to help determine the causes of the problem symptom. The potential cases of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected area in the order they are listed. Replace parts as necessary.

Entry and Start System

Symptom Suspected area See page

Ignition Switch Indicator Circuit Room Oscillator does not Recognize Key

Ignition Switch Electrical Key ID Code Box Main Body ECU

Power Source Mode does not Change

Wire Harness Push-button Start Function DTCs Power Source Mode does not Change Steering Lock System SFI System (1KR-FE) Ignition Switch Stop light switch Park/Neutral position switch Main Body ECU

Engine does not Start

Wire Harness Ignition Switch Main Body ECU Engine Switch Indicator Circuit Wire Harness

ENTRY AND START SYSTEM > PROBLEM SYMPTOMS TABLE HINT:

Use the table below to help determine the causes of the problem symptom. The potential cases of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected area in the order they are listed. Replace parts as necessary.

Entry and Start System

Symptom Suspected area See page

Ignition Switch Indicator Circuit Room Oscillator does not Recognize Key

Ignition Switch Electrical Key (TMC made) Electrical Key (TMMF made) ID Code Box Main Body ECU

Power Source Mode does not Change

Wire Harness

Entry and Start Function DTCs Power Source Mode does not Change Steering Lock System SFI System (1KR-FE) Ignition Switch Stop light switch Park/Neutral position switch Main Body ECU

Engine does not Start

Wire Harness Ignition Switch Main Body ECU Engine Switch Indicator Circuit Wire Harness

ENTRY AND START SYSTEM > TERMINALS OF ECU CHECK POWER SOURCE CONTROL ECU

1. Disconnect the 4B, 4D, 4E and D65 ECU connectors. 2. Measure the voltages and resistances of the wire harness side connectors.

Standard

Symbols (Terminal No.)

Wiring Color

Terminal Description Condition Specified

Condition BECU (4B-30) -

Body ground L - Body ground

+B power supply Always 10 to 14 V

AM1 (D65-1) - Body ground

O - Body ground


AM2 (D64-6) - Body ground

SB - Body ground


SSW1 (D65-10) - Body ground

R - Body ground

Ignition switch signal

Ignition switch pushed Below 1 Ω


R - Body ground


Ignition switch not pushed

10 kΩ or higher


L - Body ground


Ignition switch pushed Below 1 Ω


L - Body ground


Ignition switch not pushed

10 kΩ or higher

GND1 (4E-17) - Body ground

W-B - Body ground Ground Always Below 1 Ω

GND2 (D65-4) - Body ground


LIN1 (4D-9) - Body ground

P - Body ground LIN line Always 10 kΩ or

higher

3. If the result is not as specified, there may be a malfunction on the wire harness side.

4. Reconnect the 4B, 4D, 4E and D65 ECU connectors. 5. Measure the voltages of the connectors.

Standard voltage Symbols (Terminal

No.)

Wiring Color


Condition

ACCD (D64-4) - GND2

(D65-4)

LG - W-B ACC signal Ignition switch on (ACC) 10 to 14 V

ACCD (D64-4) - GND2

(D65-4)

LG - W-B ACC signal Ignition switch off Below 1 V

IG2D (D65-5) P - W- IG2 signal Ignition switch on (IG) 10 to 14 V

- GND2 (D65-4)

B

IG2D (D65-5) - GND2 (D65-4)

P - W-B IG2 signal Ignition switch on (ACC) Below 1 V

SLR+ (D64-7) - GND2

(D65-4)

L - W-B

Steering lock motor signal

Steering lock motor operating Below 1 V

SLR+ (D64-7) - GND2

(D65-4)

L - W-B

Steering lock motor signal

Steering lock motor does not operate 10 to 14 V

SLP (D64-18) - GND2 (D65-4)

GR - W-B

Steering lock actuator position

signal Steering lock locked 10 to 14 V

SLP (D64-18) - GND2 (D65-4)

GR - W-B

Steering lock actuator position

signal Steering lock released Below 1 V

SPD (4C-8) - GND2 (D65-

4)

SB - W-B

Speed signal from

combination meter

Ignition switch on (IG), Rotate driving wheel

slowly

Pulse generation

(see waveform

1)

TACH (D66-2) - GND2

(D65-4)

L - W-B

Tachometer signal Engine running

Pulse generation

(see waveform

2)

STSW (D66-4) - GND2

(D65-4)

B - W-B

Starter activation request signal

Clutch pedal (M/T) or brake pedal (except M/T) depressed, ignition switch

pushed once

10 to 14 V*

STR (D66-3) - GND2 (D65-4)

GR - W-B

Clutch pedal switch

Clutch pedal (M/T) or brake pedal (except M/T)

depressed Below 1 V

STR2 (D66-14) - GND2

(D65-4)

O - W-B Starter signal


pushed once

10 to 14 V*

INDS (D66-1) - GND2 (D65-4)

SB - W-B

Vehicle condition signal


off, on (ACC, IG)

10 to 14 V

INDW (D66-8) - GND2

(D65-4)

Y - W-B

Vehicle condition signal

Clutch pedal (M/T) or brake pedal (except M/T) released, ignition switch

off, on (ACC, IG)

10 to 14 V

STP (D64-14) - GND2 (D65-4)

G - W-B Stop light switch Brake pedal depressed Below 1 V

SWIL (D65-8) - GND2

(D65-4)

LG - W-B

Illumination signal

Light control switch TAIL or HEAD 10 to 14 V

6. HINT: 7. *: Voltage is output for 0.3 seconds after the engine is started. 8. If the result is not as specified, the ECU may have a malfunction. 9.

10. Inspect the connectors using an oscilloscope.

1. Waveform 1

Item Content Symbols

(Terminal No.) SPD (4C-8) - GND2

(D65-4)

Tool Setting 5 V/DIV., 10 msec./DIV.

Condition Driving at approx. 20 km/h (12 mph)

2. HINT: 3. As the vehicle speed increases, the wavelength shortens.

4.

5. Waveform 2


(Terminal No.) TACH (D66-2) - GND2 (D65-4)


Condition Engine idling 6. HINT:

7. As the vehicle speed increases, the wavelength shortens. CHECK CERTIFICATION ECU

1. Disconnect the D60 ECU connector. 2. Measure the voltage and resistance of the wire harness side connector.

Standard Symbols

(Terminal No.) Wiring Color


Condition +B1 (D60-1) - Body ground

B - Body ground


IG (D60-18) - Body ground

BR - Body ground

Ignition power supply

Ignition switch on (IG) 10 to 14 V

IG (D60-18) - Body ground

BR - Body ground


Ignition switch off Below 1 V

LIN (D60-10) - Body ground

P - Body ground LIN line Always 10 kΩ or

higher E (D60-17) - Body

ground W-B - Body

ground Ground Always Below 1 Ω


CHECK ECM

1. Disconnect the A32 and C33 ECM connectors. 2. Measure the voltages and resistances of the wire harness side connectors.

Standard Symbols

(Terminal No.) Wiring Color Terminal Description Condition Specified

Condition BATT (A32-

22) - E1 (A32-1)

V - W-B Battery (for measuring battery voltage and for

ECM memory) Always 10 to 14 V

+B (A32-24) - E1 (A32-1) B - W-B Power source of ECM

Ignition switch on

(IG) 10 to 14 V

+B1 (A32-23) - E1 (A32-1) B - W-B Power source of ECM

Ignition switch on

(IG) 10 to 14 V

IGSW (A32-4) - E1 (A32-1) R - W-B Ignition switch signal

Ignition switch on

(IG) 10 to 14 V

E1 (A32-1) - Body ground

W-B - Body


E2 (C33-36) - Body ground

P - Body ground Ground Always Below 1 Ω

E21 (C33-35) - Body ground

G - Body ground Ground Always Below 1 Ω

E01 (A32-20) - Body ground

W-B - Body



4. Reconnect the A32 and C33 ECM connectors. 5. Measure the voltage of the connectors.

Standard voltage Symbols

(Terminal No.) Wiring Color


Condition STA (A32-27) - BR - W- Starter relay Cranking 5.5 V or more

E1 (A32-1) B operation signal ACCR (C33-4) -

E1 (A32-1) G - W-B ACC relay cut signal (output)

Ignition switch on (IG) → Cranking

10 to 14 V → Below 1 V

TACH (A32-32) - E1 (A32-1)

LG - W-B

Engine revolution signal (output) Idling

Pulse generation

(see waveform 1)

STAR (C33-80) - E1 (A32-1) O - W-B Starter relay drive

signal Cranking 10 to 14 V

6. If the result is not as specified, the ECM may have a malfunction. 7.

8. Inspect the connector using an oscilloscope.

1. Waveform 1


(Terminal No.) TACH (A32-32) -

E1 (A32-1)


Condition Engine idling 2. HINT:

3. As the vehicle speed increases, the wavelength shortens.

CHECK STEERING LOCK ECU

1. Disconnect the D56 ECU connector. 2. Measure the voltage and resistance of the wire harness side connector.

Standard Symbols (Terminal

No.) Wiring Color


Condition B (D56-7) - Body

ground R - Body ground


IG2 (D56-6) - Body ground

R - Body ground


Ignition switch on (IG) 10 to 14 V

IG2 (D56-6) - Body ground

R - Body ground


Ignition switch off Below 1 V

GND (D56-1) - Body ground


SGND (D56-2) - Body ground



3. Reconnect the D56 ECU connector. 4. Measure the voltage of the connector.

Standard voltage

Symbols (Terminal No.)

Wiring Color Terminal Description Condition Specified

Condition SLP1 (D56-4) - GND (D56-1)

GR - W-B

Steering lock actuator position signal

Steering lock locked 10 to 14 V

SLP1 (D56-4) - GND (D56-1)

GR - W-B

Steering lock actuator position signal

Steering lock released Below 1 V

1. If the result is not as specified, the ECU may have a malfunction.

ENTRY AND START SYSTEM > DIAGNOSIS SYSTEM

CHECK DLC3

1. The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format.

Symbols (Terminal No.) Terminal Description Condition Specified

Condition

SIL (7) - SG (5) Bus " +" line During transmission Pulse generation

CG (4) - Body ground Chassis ground Always Below 1 Ω

SG (5) - Body ground Signal ground Always Below 1 Ω

BAT (16) - Body ground Battery positive Always 10 to 14 V

CANH (6) - CANL (14) CAN bus line Ignition switch

off* 54 to 69 Ω

CANH (6) - CG (4) HIGH-level CAN bus line

Ignition switch off* 200 Ω or higher

CANL (14) - CG (4) LOW-level CAN bus line

Ignition switch off* 200 Ω or higher

CANH (6) - BAT (16)

HIGH-level CAN bus line

Ignition switch off* 6 kΩ or higher

CANL (14) - BAT (16)

LOW-level CAN bus line

Ignition switch off* 6 kΩ or higher

2. NOTICE: 3. *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and

do not operate the ignition switch, any other switches or the doors. 4. If the result is not as specified, the DLC3 may have a malfunction. Repair or

replace the harness and connector.

HINT:

Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester.

• If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle.

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

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

11 to 14 V

ENTRY AND START SYSTEM > DTC CHECK / CLEAR CHECK DTC

1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) and turn the intelligent tester ON. 3. Select the following menu items: Body / Body ECU / DTC. 4. Check DTCs and then write them down.

HINT: For further information about using the intelligent tester, refer to the instruction manual.

5. Confirm the details of the DTCs.

CLEAR DTC (using the intelligent tester)

1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) (do not start the engine) and turn the intelligent

tester ON. 3. Select the following menu items: Body / Body ECU / DTC / Clear.

HINT: Refer to the intelligent tester operator's manual for further details.

4. Erase DTCs by pressing the YES button on the tester.

HINT: For further information about using the intelligent tester, refer to the instruction manual.

CLEAR DTC (not using the intelligent tester)

1. Remove the ECU-B fuse from the engine room R/B for more than 60 seconds, or disconnect the negative battery cable for more than 60 seconds.

ENTRY AND START SYSTEM > DATA LIST / ACTIVE TEST DATA LIST

HINT: Using the intelligent tester's Data List allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the Data List in troubleshooting is one way to save time.

NOTICE: In the table below, the values listed under Normal Conditions are for reference only. Do not depend solely on these values when determining whether or not a part is faulty.

1. Turn the ignition switch off. 2. Connect the intelligent tester to the DLC3. 3. Turn the ignition switch on (IG) and turn the tester ON. 4. Select the following menu items: Body / Body ECU / Data List. 5. Check the values by referring to the table below.

Main body ECU

Item Measurement Item / Display (Range) Normal Condition Diagnostic

Note

IG SW Ignition switch / ON or OFF ON: Ignition switch is on (IG) OFF: Ignition switch is off

-

ACC SW Ignition switch / ON or OFF ON: Ignition switch is on (ACC) OFF: Ignition switch is off

-

St SW1 Start switch 1 / ON or OFF ON: Ignition switch is on (IG) OFF: Ignition switch is off

-

St SW2 Start switch 2 / ON or OFF ON: Ignition switch is on (IG) OFF: Ignition switch is off

-

Str Unlock

SW

Steering lock condition / ON or OFF

ON: Steering is unlocked OFF: Steering is locked -

N SW / C SW

Clutch switch (M/T) or park/neutral position switch (except M/T)/ ON or OFF

ON: Clutch pedal is depressed (M/T) or Shift position is N (except M/T) OFF: Clutch pedal is released or Shift position is except N (except M/T)

-

Stop Lamp Stop light switch/ ON or OFF ON: Brake pedal is

depressed -

SW1 OFF: Brake ped Vehicle Spd Sig

Vehicle speed signal / STOP or RUN

STOP: Vehicle is stopped RUN: Vehicle is running -

E/G Cond Engine condition / STOP or RUN

STOP: Engine is stopped RUN: Engine is running -

IG1 Relay Mon1

IG1 outer relay monitor / ON or OFF

ON: Ignition switch is on (IG) OFF: Ignition switch is off

-

IG2 Relay Mon1

IG2 outer relay monitor / ON or OFF


-

IG1 Relay Mon2

IG1 inner relay monitor / ON or OFF


-

IG2 Relay Mon2

IG2 inner relay monitor / ON or OFF


-

ACC Relay Mon

ACC relay monitor / ON or OFF

ON: Ignition switch is on (ACC) OFF: Ignition switch is off

-

Ratch Circuit Ratch circuit / ON or OFF

ON: Ignition switch is on (IG) OFF: Ignition switch is off, on (ACC) or engine is running

-

Start Req Sig

Starter request signal / ON or OFF

ON: ST relay is ON OFF: ST relay is OFF -

Pwr Cond Power supply condition /

ALL, ACC ON, IG1 IG2, ST ON

ALL: All relays are ON ACC ON: ACC relay is ON IG1: IG1 relay is ON IG2: IG2 relay is ON ST ON: ST relay is ON

-

#Code Number of diagnosis codes / Min: 0, max: 255 - -

6.

Certification ECU

Item Measurement Item / Range (Display) Normal Condition Diagnostic

Note

IG SW Ignition switch / ON or OFF


-

ACC SW Ignition switch / ON or OFF

ON: Ignition switch is on (ACC) OFF: Ignition switch is off

-

Key Lo-batt Wrn

Electrical key battery conditions / ON or OFF

ON: Battery has been depleted OFF: Battery is not depleted

-

Unmatch Format Code format/ YES or NO

YES: Code format matches NO: Code format differs

-

No response Response/ YES or NO YES: Response

NO: No response -

Wrong Code ID code/ YES or NO

YES: ID code matches NO: ID code differs

-

Wrong C Code Challenge code/ YES or NO

YES: Challenge code matches NO: Challenge code differs

-

Unmatch V-ID Key number/ YES or NO

YES: Key number matches NO: Key number differs

-

Permit (Start)

Engine start permission by certification ECU/ PERMIT or

PROHIBIT

PERMIT: Engine start is permitted PROHIBIT: Engine start is prohibited

-

Start Rqst Starter request signal / ON or OFF

YES: Engine switch off NO: ST relay is OFF

-

S Code Chk

S code certification result/ NG or OK

NG: S code certification result is abnormal OK: S code certification result is normal

-

L Code Chk

L code certification result/ NG or OK

NG: L code certification result is abnormal OK: L code certification result is normal

-

ACTIVE TEST HINT:

Performing an Active Test enables components including the relays, VSV (Vacuum Switching Valve), and actuators, to be operated without removing any parts. The Active Test can be performed with an intelligent tester. Performing an Active Test as the first step of troubleshooting is one method of shortening diagnostic time. Data List can be displayed during Active Tests.

1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch to on (IG). 3. Turn the tester ON. 4. Select the following menu items: Body / Body ECU / Active Test. 5. Perform the Active Test by referring to the table below.

Main body ECU Item Test Details Diagnostic Note

Lighting Ind Indicator illumination ON/OFF -

Ind Condition Indicator light illumination pattern Green/Amber/No Sig -

S Lock Pwr Steering lock ECU power supply ON/OFF -

Certification ECU Item Test Details Diagnostic Note

Fr Transmitter Indoor electrical key antenna (front) ON / OFF -

ENTRY AND START SYSTEM > DIAGNOSTIC TROUBLE CODE CHART

• If a trouble code is displayed during the DTC check, inspect the suspected areas listed for that code. For details of the code, refer to the "See page" in the DTC chart.

• Inspect the fuse and relay before investigating the suspected areas shown in the table below.

Entry and Start System DTC No. Detection Item Trouble Area See

page

B2271 Ignition Hold Monitor Malfunction - Main body ECU - AM2 fuse - Wire harness

B2272 Ignition 1 Monitor Malfunction - Main body ECU - IG1 relay - Wire harness

B2273 Ignition 2 Monitor Malfunction - Main body ECU - IG2 relay - Wire harness

B2274 ACC Monitor Malfunction - Main body ECU - ACC cut relay - Wire harness

B2275 STSW Monitor Malfunction - Main body ECU - SFI system - Wire harness

B2276 ACCR Signal Circuit Malfunction - Main body ECU - SFI system - Wire harness

B2277 Detecting Vehicle Submersion Main body ECU

B2278 Engine Switch Circuit Malfunction - Main body ECU - Ignition switch - Wire harness

B2282 Vehicle Speed Signal Malfunction - Main body ECU - Combination meter - Wire harness

B2283 Vehicle Speed Sensor Malfunction

- Main body ECU - Combination meter - Speed sensor - Skid control ECU - Wire harness

B2285 Steering Lock Position Signal Circuit Malfunction

- Main body ECU - Steering lock system - Wire harness

B2286 Runnable Signal Malfunction - Main body ECU - SFI system - Wire harness

B2287 LIN Communication Master Malfunction - Main body ECU - Certification ECU - Wire harness

B2288 Steering Lock Signal Circuit Malfunction - Main body ECU - Steering lock system - Wire harness

B2289 Key Collation Waiting Time Over

- Main body ECU - Entry function - Engine immobiliser system - Ignition switch - Electrical key - Wire harness

ENTRY AND START SYSTEM > Power Source Mode does not Change

DESCRIPTION When the certification ECU has detected the electrical key inside the cabin, the power source mode can be changed in the following order sequentially by pressing the ignition switch: Off → On (ACC) → On (IG) → Off. When either one of the DTCs shown in the illustration below is detected, troubleshoot the DTC(s) by following the troubleshooting procedure relevant to the DTC(s). If the power source mode is still not changed normally, despite troubleshooting, one of the following may have occurred:

• The LIN communication line is malfunctioning. • The certification ECU has determined that no key is inside the cabin. • The ignition switch is malfunctioning. • The main body ECU is malfunctioning.

INSPECTION PROCEDURE

1.CHECK WHETHER DTC OUTPUT RECURS

1. Clear the DTCs.

HINT: After all DTCs are cleared, check if the trouble occurs again 5 seconds after the ignition switch is turned on (IG).

2. Check for DTCs again.

OK: No DTC is output.

NG

GO TO DTC CHART

OK

2.CHECK BASIC FUNCTION

1. Carry the key into the vehicle.

2. Depress the clutch pedal (M/T) or brake pedal (except M/T) and check that the ignition switch indicator illuminates in green.

OK: Ignition switch indicator illuminates in green.

NG

Go to step 10

OK

3.INSPECT FUSE (AM2)

1. Remove the AM2 fuse from the engine room R/B and J/B.

2. Check the fuse resistance.

Standard resistance: Below 1 Ω

3. Reinstall the AM2 fuse.

NG

REPLACE FUSE

OK

4.READ VALUE OF INTELLIGENT TESTER (RELAY MONITOR)

1. Connect the intelligent tester to the DLC3.

2. Turn the ignition switch on (IG) and turn the tester ON.

3. Select the following menu items: Body/ Main Body ECU/ Data List / IG1 Relay Mon2, IG2 Relay Mon2 and ACC Relay Monitor.

4. Read the display on the tester.

Main Body ECU:

Item Measurement Item / Display (Range) Normal Condition

IG1 Relay Mon2 IG1 inner relay monitor / ON or OFF

ON: Ignition switch on (IG)

OFF: Ignition switch off

IG2 Relay Mon2 IG2 inner relay monitor / ON or OFF

ON: Ignition switch on (IG)

OFF: Ignition switch off

ACC Relay Monitor ACC relay monitor / ON or OFF

ON: Ignition switch on (ACC)

OFF: Ignition switch off OK: ON appears on the screen.

OK

REPLACE MAIN BODY ECU

NG

5.INSPECT RELAYS (IG1RELAY, IG2 RELAY AND ACC CUT RELAY)

1. Inspect the IG1 relay. 1. Remove the IG1 relay from the main body ECU. 2. Check the resistance.

Standard resistance: Tester

Connection Specified Condition

3 - 5 10 kΩ or higher

3 - 5

Below 1 Ω (When battery

voltage applied to terminals 1 and 2)

3. Reinstall the IG1 relay.

2. Inspect the integration relay (IG2 relay). 1. Remove the integration relay from the engine R/B and J/B.

2. Measure the resistance.



1B-4 - 1C-1 10 kΩ or higher

1B-4 - 1C-1


voltage applied to terminals 1B-2 and

1B-3)

3. Reinstall the integration relay.

3. Inspect the ACC cut relay. 1. Remove the ACC cut relay. 2. Check the resistance.



3 - 5 10 kΩ or higher

3 - 5


voltage applied to terminals 1 and 2)

3. Reinstall the relay.

NG

REPLACE RELAY

OK

6.CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - INTEGRATION RELAY (IG2 RELAY))

1. Remove the integration relay from the engine R/B and J/B.

2. Disconnect the D65 main body ECU connector.

3. Measure the resistance of the wire harness side connectors.

Standard resistance:

Tester Connection Specified Condition

1B-2 (Integration relay) - D65-5 (IG2D) Below 1 Ω

1B-3 (Integration relay) - Body ground Below 1 Ω

1B-2 (Integration relay) or D65-5 (IG2D) -

Body ground

10 kΩ or higher

4. Reinstall the integration relay.

5. Reconnect the ECU connector.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

7.CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - ACC CUT RELAY)

1. Remove the ACC cut relay.





ACC cut relay (D73-2) - ACCD (D64-4) Below 1 Ω

4. Reinstall the ACC cut relay.

5. Reconnect the main body ECU connector.

NG


OK

8.INSPECT IGNITION SWITCH ASSEMBLY

1. Remove the ignition switch.

2. Measure the resistance of the switch.


Connection Switch

Condition Specified Condition

7 (SS1) - 5 (GND) Pushed Below 1 Ω


7 (SS1) - 5 (GND) Not pushed 10 kΩ or

higher 2 (SS2) - 5

(GND) Not pushed 10 kΩ or higher

3. Reinstall the ignition switch.

NG

REPLACE IGNITION SWITCH ASSEMBLY

OK

9.CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - BATTERY AND BODY GROUND)

1. Disconnect the D64 and D65 main body ECU connectors.

2. Measure the voltage and resistance of the wire harness side connector.

Standard voltage:


D65-1 (AM1) - Body ground 10 to 14 V

D64-6 (AM2) - Body ground 10 to 14 V



D65-4 (GND2) - Body ground Below 1 Ω

3. Reconnect the main body ECU connectors.

NG


OK

REPLACE MAIN BODY ECU 10.CHECK WIRELESS DOOR LOCK AND UNLOCK OPERATION

1. Check that the wireless door lock and unlock functions operate normally.

OK: Wireless door lock functions operate normally.

NG

GO TO WIRELESS DOOR LOCK CONTROL SYSTEM

OK

11.CHECK OPERATION OF ELECTRICAL KEY

1. After replacing the electrical key with a normally functioning one, check that the wireless lock and unlock functions operate normally.

OK: Wireless lock and unlock functions operate normally.

OK

END (ELECTRICAL KEY IS DEFECTIVE)

NG

12.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INDOOR ELECTRICAL KEY OSCILLATOR)

1. Select the Active Test, use the intelligent tester to generate a control command, and then check that the oscillator operates.

Certification ECU:

Item Test Details Diagnostic Note

Fr Transmitter Indoor electrical key oscillator (front) ON / OFF -

OK: Oscillator function operate normally.

OK

GO TO ROOM OSCILLATOR DOES NOT RECOGNIZE KEY (DOOR LOCK SECTION)

NG

13.CHECK INDOOR ELECTRICAL KEY OSCILLATOR

1. Carry the key into the vehicle.

2. Replace the indoor electrical key oscillator with a new one.

3. Depress the clutch pedal (M/T) or brake pedal (except M/T) and check that the ignition switch indicator illuminates in green.

OK: Ignition switch indicator illuminates in green.

NG

REPLACE CERTIFICATION ECU

OK

END (INDOOR ELECTRICAL KEY OSCILLATOR IS DEFECTIVE)

ENTRY AND START SYSTEM > Engine does not Start

DESCRIPTION ENGINE START SYSTEM OPERATION

1. Except M/T: If the engine switch is pressed with the shift lever in P (A/T) or N and the brake pedal depressed, the main body ECU determines that it is an engine start request.

2. M/T: When the ignition switch is pressed with the clutch pedal depressed, the main body ECU determines that it is an engine start request.

3. The certification ECU and other ECUs perform key verification via the LIN communication line.

4. The main body ECU activates the ACC cut relay. 5. The main body ECU activates the IG1 and IG2 relays. The ignition switch

indicator light illuminates green. 6. The certification ECU outputs a steering UNLOCK signal. The signal is sent to

the steering lock ECU via the main body ECU. 7. The main body ECU sends an engine start request signal to the ECM. 8. The ECM sends an ACC cut request signal to the main body ECU. 9. The ECM and main body ECU activate the ST relay. 10. The main body ECU deactivates the ACC cut relay until the ECU detects an

engine start. 11. The ECU reactivates the ACC cut relay and turns off the ignition switch indicator

light.

Symbols of main body ECU Signals STP Stop light switch ON signal

SSW1/SSW2 Ignition switch ON signal ACCD ACC cut relay operation signal IG2D IG2 relay operation signal STR2 ST relay operation signal

STR Clutch switch signal (M/T) ST relay operation signal (except M/T)

TACH Engine start detection signal STSW Starter activation request signal ACCR ACC cut request signal

WIRING DIAGRAM See CRANKING HOLDING FUNCTION CIRCUIT ().


1.CHECK WHETHER ENGINE STARTS AFTER STEERING LOCK INITIALIZATION

1. Open and close the driver door when the ignition switch is off.

2. Check that the engine starts.

OK: Engine starts.

HINT: The engine may not start if the steering lock ECU has not been initialized through the procedure described in above after the battery runs out.

OK

SYSTEM OK

NG

2.CHECK WHETHER DTC OUTPUT RECURS

1. Clear the DTCs.

HINT: After all DTCs are cleared, check if the trouble occurs again 5 seconds after the ignition switch is turned on (IG).

2. Check for DTCs again.

OK: No DTC is output.

NG

GO TO DTC CHART

OK

3.CHECK SWITCH CONDITION

1. Ensure the electrical key is inside the cabin.

2. Check that the power source mode changes as shown below each time the ignition switch is.

OK: off → on (ACC) → on (IG) → off

NG

GO TO POWER SOURCE MODE DOES NOT CHANGE

OK

4.CHECK BASIC FUNCTION

1. Ensure there is fuel in the fuel tank and the key is inside the cabin.

2. Depress the clutch pedal (M/T) or brake pedal (except M/T), and keep depressing the pedal.

3. Check that the engine cranks when the ignition switch is pressed.

OK: Engine cranks.

OK

Go to step 8

NG

5.READ VALUE OF INTELLIGENT TESTER (CLUTCH START SW, PARK/NEUTRAL POSITION SW AND STOP LIGHT SW)



3. For except M/T: 1. Select the following menu items: Body / Main Body ECU / Data List /

Stop Lamp SW1. 2. Read the display on the tester.

Main body ECU:

Item Measurement Item/Display (Range) Normal Condition Diagnostic

Note

Stop Lamp SW1

Stop light switch 1/ ON or OFF

ON: Brake pedal depressed

OFF: Brake pedal released

-

OK: ON (brake pedal depressed) and OFF (brake pedal released) appear on the screen.

4. Select the following menu items: Body / Main Body ECU / Data List / N SW / C SW.


Main body ECU:

Item Measurement Item/Display (Range) Normal Condition Diagnostic

Note

N SW / C SW

Clutch switch (M/T) or park/ neutral position switch (except

M/ T)/ ON or OFF

ON: Clutch pedal is depressed (M/T) or Shift

position is N (except M/T)

-

OFF: Clutch pedal is released or Shift position is except N (except M/T)

OK: ON (Clutch pedal is depressed (M/T) or Shift position is N (except M/T)) and OFF ( Clutch pedal is released or Shift position is except N (except M/T)) appear on the screen.

NG

REPAIR OR REPLACE CLUTCH START SWITCH

OK

6.CHECK STEERING LOCK SYSTEM

1. When the ignition switch is on (ACC), check that the steering lock can be released.

OK: Steering lock can be released.

NG

GO TO STEERING LOCK SYSTEM

OK

7.INSPECT MAIN BODY ECU


2. Depress the clutch pedal, and keep depressing the pedal.

3. Measure the voltage when the engine cranks by pressing the ignition switch.

Standard voltage:


STSW (D66-4) - Body ground 10 to 14 V

4. Reconnect the main body ECU connector.

NG

GO TO SFI SYSTEM (CRANKING HOLDING FUNCTION CIRCUIT)

OK

REPLACE MAIN BODY ECU 8.READ VALUE OF INTELLIGENT TESTER (L CODE CHECK)

1. Placs the electrical key is inside the vehicle.



4. Select the following menu items: Body / Certification ECU / Data List / L Code Chk.


Certification ECU:


L Code Chk L Code Check / NG or OK

NG: L code certification result is abnormal OK: L code certification result is normal

OK: L code certification result is normal.

NG

GO TO ENGINE IMMOBILISER SYSTEM (STEERING LOCK ECU OR ID CODE BOX MALFUNCTIONS)

OK

9.READ VALUE OF INTELLIGENT TESTER (ENGINE START REQUEST)


2. Turn the ignition switch on (IG) and turn the tester ON (not start the engine).

3. Select the following menu items: Body / Certification ECU / Data List / Start Req Sig.

4. Read the displays on the tester.

Certification ECU:


Start Req Sig Starter request signal / Yes or No Yes: ST relay is ON No: ST relay is OFF

OK: ST relay is ON.

NO

REPLACE CERTIFICATION ECU

YES

10.READ VALUE OF INTELLIGENT TESTER (S CODE CHECK)



3. Select the following menu items: Body / Certification ECU / Data List / S Code Chk.


Certification ECU:


S Code Chk S Code Check / NG or OK

NG: S code certification result is abnormal OK: S code certification result is normal

OK: S code certification result is normal.

NG

GO TO ENGINE IMMOBILISER SYSTEM (CERTIFICATION ECU OR ID CODE BOX MALFUNCTIONS)

OK

REPLACE ID CODE BOX

ENTRY AND START SYSTEM > Engine Switch Indicator Circuit

DESCRIPTION Engine start conditions or system malfunctions can be checked by observing the status of the ignition switch indicator light.

Ignition switch indicator light condition Indicator Light Condition

Power Source Mode/Condition

Clutch pedal released (M/T)

Brake pedal released (except M/T)

Clutch pedal depressed (M/T)

Brake pedal depressed (except M/T)

Off OFF Illuminates (Green)

On (ACC, IG) Illuminates (Amber) Illuminates (Green) Engine running OFF OFF

Steering lock not unlocked Flashes (Green) for 15 seconds


System malfunction Flashes (Amber) for 15 seconds

Flashes (Amber) for 15 seconds

Clutch switch malfunction (M/T)



WIRING DIAGRAM


1.INSPECT IGNITION SWITCH ASSEMBLY

1. Remove the ignition switch.

2. Apply the battery voltage between the terminals of the switch, and check the illumination condition of the ignition switch indicator light.

NOTICE:

• If the positive (+) lead and the negative (-) lead are incorrectly connected, the ignition switch indicator light does not illuminate.

• If the voltage is too low, the indicator light does not illuminate.

OK: Measurement

Condition Specified Condition

Battery positive (+) → Terminal 11 (SWIL)

Battery negative (-) → Terminal 4 (COM) or 5

(GND)

Illuminates

Battery positive (+) → Terminal 12 (INDS)


(GND)

Illuminates

Battery positive (+) → Terminal 13 (INDW)


(GND)

Illuminates

3. Reinstall the ignition switch.

NG

REPLACE IGNITION SWITCH ASSEMBLY

OK

2.CHECK HARNESS AND CONNECTOR (IGNITION SWITCH - MAIN BODY ECU AND BODY GROUND)

1. Disconnect the D55 ignition switch connector.

2. Disconnect the D65 and D66 main body ECU connectors.




D55-11 (SWIL) - D65-8 (SWIL) Below 1 Ω

D55-12 (INDS) - D66-1 (INDS) Below 1 Ω

D55-13 (INDW) - D66-8 (INDW) Below 1 Ω

D55-5 (GND) - Body ground Below 1 Ω

D55-4 (COM) - Body ground Below 1 Ω

D55-11 (SWIL) or D65-8 (SWIL) - Body

ground

10 kΩ or higher

D55-12 (INDS) or D66-1 (INDS) - Body

ground

10 kΩ or higher

D55-13 (INDW) or D66-8 (INDW) - Body

ground

10 kΩ or higher

4. Reconnect the main body ECU connectors.

5. Reconnect the ignition switch connector.

NG


OK

REPLACE MAIN BODY ECU

STARTER (for 0.8 kW Type) > COMPONENTS

2 / 2

STARTER (for 0.8 kW Type) > REMOVAL

1. REMOVE BATTERY

1. Disconnect the negative battery terminal.

2. Disconnect the positive battery terminal.

3. Loosen the nut, and remove the battery carrier clamp.

4. Remove the battery from the vehicle.

2. REMOVE BATTERY TRAY 3. REMOVE FLYWHEEL HOUSING SIDE COVER

1. Disengage the claw while pushing it downward and remove the flywheel housing side cover.

4. REMOVE STARTER ASSEMBLY

1. Separate the harness clamp.

2. Remove the bolt and remove the wire harness bracket.

3. Remove the terminal cap.

4. Separate the harness clamp.

5. Remove the nut and disconnect terminal 30.

6. Disconnect the connector.

7. Remove the 2 bolts and remove the starter assembly.

STARTER (for 0.8 kW Type) > DISASSEMBLY 1. REMOVE MAGNET STARTER SWITCH ASSEMBLY

1. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.

2. Remove the 2 nuts holding the magnetic switch onto the starter housing.

3. Pull the magnetic switch and while lifting the front part of the magnetic switch, release the plunger hook from the driver lever, then remove the magnetic switch.

2. REMOVE STARTER YOKE ASSEMBLY

1. Remove the 2 through bolts and end cover.

2. Hold the starter drive housing in a vise between alminum plates.

NOTICE: Do not overtighten the vise.

3. Remove the plate and 4 brush springs.

4. Disconnect the 4 brushes, and remove the brush holder.

5. Remove the starter yoke assembly.

3. REMOVE ARMATURE

1. Pull the armature together with the drive lever out of the starter housing.

2. Remove the drive lever from the armature.

4. REMOVE STARTER CLUTCH SUB-ASSEMBLY

1. Using a screwdriver, tap the inside stop collar toward the armature.

2. Using a screwdriver, pry off the snap ring.

3. Pull the stop collar and starter clutch out of the armature.

STARTER (for 0.8 kW Type) > INSPECTION 1. INSPECT STARTER ASSEMBLY NOTICE:

Perform each of the following tests within 3 to 5 seconds.

1. Perform pull-in test.

1. Disconnect the field coil lead wire from terminal C.

2. Connect the battery to the starter magnetic switch as shown in the illustration and check that the pinion gear is extended.

2. Perform holding test.

1. Check that the pinion gear does not return inward after the cable of terminal C is disconnected.

3. Inspect the clutch pinion gear return.

1. Move the pinion gear toward the armature.

4. Perform the operation test without load.

1. Connect the field coil lead wire to terminal C.

Torque: 9.8 N*m 100 kgf*cm , 7.2 ft.*lbf

2. Clamp the starter in a vise.

3. Connect the battery and ammeter to the starter as shown in the illustration. 4. Check that the ammeter indicates the specified current.

Standard current: 50A or less at 11.5 V

2. INSPECT STARTER ARMATURE ASSEMBLY

1. Check the commutator for open circuits.

1. Using an ohmmeter, check the resistance between the segments of the commutator.


If the result is not as specified, replace starter armature assembly.

2. Check the commutator for ground.

1. Using an ohmmeter, check the resistance between the commutator and armature core.

Standard resistance: 10 kΩ or higher

If the result is not as specified, replace the starter armature assembly.

3. Check the commutator for dirt and burns on the surface. If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.

4. Check the commutator circumference runout.

1. Place the commutator on V-blocks. 2. Using a dial indicator, measure the circumference runout.

Maximum runout: 0.4 mm (0.0157 in.)

If the runout is greater than the maximum, replace the starter armature assembly.

5. Using vernier calipers, measure the commutator diameter.

Standard diameter: 28.0 mm (1.1024 in.) Minimum diameter: 27.0 mm (1.0630 in.)

If the diameter is less then the minimum, replace the starter armature assembly.

6. Using vernier calipers, measure the undercut depth of the commutator.

Standard depth: 0.6 mm (0.0236 in.) Minimum depth: 0.2 mm (0.0079 in.)

If the undercut depth is less then the minimum, adjust it with a hacksaw blade.

3. INSPECT STARTER YOKE ASSEMBLY

1. Using an ohmmeter, check the resistance between terminal C and the field coil brush lead (+).

NOTICE: Check the resistance between terminal C and the 2 brush leads (+). Standard resistance: Below 1 Ω

If the result is not as specified, replace the starter yoke assembly.

2. Using an ohmmeter, check the resistance between the brush lead (+) and the starter yoke.

NOTICE: Check the resistance between the brush lead (-) and the starter yoke. Standard resistance: Below 1 Ω

If the result is not as specified, replace the starter yoke assembly.

4. INSPECT BRUSH

1. Using vernier calipers, measure the brush length.

Standard length: 10 mm (0.3937 in.) Minimum length: 6 mm (0.2362 in.)

If the length is less than the minimum, replace the starter yoke assembly.

5. INSPECT STARTER CLUTCH SUB-ASSEMBLY

1. Hold the starter clutch and rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. If necessary, replace the starter clutch sub-assembly.

6. INSPECT MAGNET STARTER SWITCH ASSEMBLY

1. Check the plunger.

1. Push in the plunger and check that it returns quickly to its original position. If necessary, replace the magnet starter switch assembly.

2. Check the pull-in coil for an open circuit.

1. Using an ohmmeter, check the resistance between terminals 50 and C.


If the result is not as specified, replace the magnet starter switch assembly.

3. Check whether the holding coil has an open circuit.

1. Using an ohmmeter, check the resistance between terminal 50 and the switch body.


If the result is not as specified, replace the magnet starter switch assembly.

STARTER (for 0.8 kW Type) > REASSEMBLY 1. INSTALL STARTER CLUTCH SUB-ASSEMBLY

1. Apply grease to the bushing and spline of the starter clutch.

2. Place the starter clutch and inside stop collar on the armature.

3. Apply grease to the snap ring, and install it onto the armature shaft groove.

4. Using a vise, compress the snap ring.

5. Hold the starter clutch, tap the armature shaft and install the stop collar onto a new snap ring with a plastic-faced hammer.

2. INSTALL STARTER ARMATURE ASSEMBLY

1. Apply grease to the drive lever that is in contact with the starter pivot part of the drive lever.

2. Install the drive lever onto the starter clutch.

3. Install the armature together with the drive lever onto the starter housing.

3. INSTALL STARTER YOKE ASSEMBLY

1. Align the cutout of the starter yoke assembly with the protrusion of the starter lever.

2. Hold the starter drive housing in a vice between aluminum plates.

NOTICE: Do not overtighten the vise.

3. Install the brush holder, and connect the 4 brushes into the brush holder.

4. Install the 4 brush springs and plate.

NOTICE: Check that positive (+) lead wires are not grounded.

5. Install the end cover with the 2 through bolts.

Torque: 5.9 N*m 60 kgf*cm , 52 in.*lbf

4. INSTALL MAGNET STARTER SWITCH ASSEMBLY

1. Hang the plunger of the magnetic switch onto the drive lever from the upper side.

2. Install the magnetic switch with the 2 nuts.


3. Connect the lead wire to the terminal, and install the nut.


STARTER (for 0.8 kW Type) > INSTALLATION 1. INSTALL STARTER ASSEMBLY

1. Install the starter assembly with the 2 bolts.

Torque: 37 N*m 377 kgf*cm , 27 ft.*lbf

2. Connect the connector.

3. Connect terminal 30 with the nut.

Torque: 9.8 N*m 100 kgf*cm , 7.2 ft.*lbf

4. Close the terminal cap.

5. Install the wire harness bracket with the bolt.

Torque: 8 N*m 82 kgf*cm , 71 in.*lbf

6. Install the harness clamp.

2. INSTALL FLYWHEEL HOUSING SIDE COVER

1. Insert the protruding portion into the end of the cylinder block and while pushing it along the cylinder block, fit the claw into the cylinder block.

NOTICE:

• Make sure that the claw makes a click sound, indicating that it fits tightly. • Replace the claw with a new one if it does not fit tightly or is deformed.

3. INSTALL BATTERY TRAY 4. INSTALL BATTERY

1. Install the battery onto the battery tray.

2. Install the battery carrier clamp with the nut.

3. Install the positive and negative terminals.


3 / 3


2 / 2


3 / 3

STARTER RELAY > ON-VEHICLE INSPECTION

1. INSPECT STARTER RELAY ASSEMBLY

1. Check the resistance.

1. Using an ohmmeter, measure the resistance between the terminals.



Below 1 Ω (when battery voltage

applied to terminals 1 and 2)

3 - 5

10 kΩ or higher

If the result is not as specified, replace the relay.

STARTER CUT RELAY (w/ Entry and Start System) > COMPONENTS

4 / 4

STARTER CUT RELAY (w/ Entry and Start System) > REMOVAL

1. BOLTS, SCREWS AND NUTS TABLE HINT:

All bolts, screws and nuts relevant to installing and removing the instrument panel are shown, along with their alphabetic codes, in the table below.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE INSTRUMENT PANEL FINISH PANEL END LH

1. with CD player

1. Pull the instrument panel finish panel end LH rearward and disengage the 4 claws and 3 clips.

NOTICE: To avoid damaging the radio receiver and the air conditioning panel, remove the instrument panel finish panel end without using any tool.

HINT: Grip portion A of the instrument panel finish panel end and remove the instrument panel finish panel end from the lower side.

2. Disconnect the connector and remove the instrument panel finish panel end LH.

2. Except CD player

1. Pull the instrument panel finish panel end LH rearward and disengage the 5 claws and 3 clips.

NOTICE: To avoid damaging the instrument cluster finish panel center and the air conditioning panel, remove the instrument panel finish panel end without using any tool.


2. Disconnect the connector and remove the instrument panel finish panel end LH.

4. REMOVE INSTRUMENT PANEL FINISH PANEL END RH

1. with CD player

1. Pull the instrument panel finish panel end RH and disengage the 4 claws and 3 clips.

NOTICE: To avoid damaging the radio receiver and the air conditioning panel, remove the instrument panel finish panel end without using any tool.


2. Disconnect the connector and remove the instrument panel finish panel end RH.

2. Except CD player

1. Pull the instrument panel finish panel end RH rearward and disengage the 5 claws and 3 clips.

NOTICE: To avoid damaging the instrument cluster finish panel center and the air conditioning panel, remove the instrument panel finish panel end without using any tool.


2. Disconnect the connector and remove the instrument panel finish panel end RH.

5. REMOVE INSTRUMENT CLUSTER FINISH PANEL

NOTICE: Follow the procedure below to remove the instrument cluster finish panel. Claw A will break if the instrument cluster finish panel is raised carelessly.

1. Disengage the 2 claws and 5 clips.

2. After removing the instrument panel finish panel end, insert your finger into the opening as shown, push the upper portion of the instrument cluster finish panel center and the 2 B claws of the instrument cluster finish panel, and then disengage the claws B.

3. Disengage the 3 A claws and remove the instrument cluster finish panel.

6. REMOVE COMBINATION METER ASSEMBLY

1. Disconnect the 2 connectors.

2. Remove the 2 screws and pull the combination meter rearward to remove it.

7. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH

1. Separate the front door opening trim weatherstrip.

8. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH

1. Separate the front door opening trim weatherstrip.

9. REMOVE FRONT PILLAR GARNISH RH

1. w/ Curtain Shield Airbag:

NOTICE:

• Install a protective cover onto the curtain shield airbag as soon as the front pillar garnish is removed.

• Replace the special clip with a new one when the front pillar garnish is removed.

3. Disengage the 2 clips and the 2 claws and remove the front pillar garnish.

2. w/o Curtain Shield Airbag:



4. Using a clip remover, remove the 3 antenna cord clamps.

5. w/ Front No. 2 Speaker:

1. Disconnect the speaker connector.

2. Using a screwdriver with its tip wrapped in protective tape, disengage the clip and hook and remove the front No. 2 speaker.


1. Completely cover the curtain shield airbag with a piece of cloth or nylon and fix the ends of the fabric with adhesive tape, as shown in the illustration.

Protective cover size: Area Measurement a 700 mm (27.56 in.) b 120 mm (4.72 in.)

10. REMOVE FRONT PILLAR GARNISH LH


NOTICE:

• Install a protective cover onto the curtain shield airbag as soon as the front pillar garnish is removed.

• Replace the special clip with a new one when the front pillar garnish is removed.




3. Using a clip remover, remove the 4 wire harness clamps.


1. Disconnect the speaker connector.

2. Using a screwdriver with its tip wrapped in protective tape, disengage the clip and hook and remove the front No. 2 speaker.


1. Completely cover the curtain shield airbag with a piece of cloth or nylon and fix the ends of the fabric with adhesive tape, as shown in the illustration.

Protective cover size: Area Measurement a 700 mm (27.56 in.) b 120 mm (4.72 in.)

11. REMOVE SWITCH HOLE BASE

1. Disengage the 2 clips and 2 claws and remove the switch hole base.

12. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

1. Slightly deform the upper part of the glove compartment door assembly to release the 2 stoppers and open the glove compartment door assembly until it becomes horizontal.

2. Pull the glove compartment door assembly out horizontally to disengage the hinge portion and remove the glove compartment door assembly.

NOTICE: Pull the glove compartment door out horizontally, otherwise, installation failure caused by excessive play around the hinge portion will result.

13. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER

1. Slide the slider and disconnect the passenger airbag connector.

2. Disconnect the clamp.

3. Remove the 2 <C> bolts and 4 <B> screws.

4. Disconnect the connectors.

5. Disengage the claw and 3 clips while lifting the rear instrument panel up.

6. While lifting the instrument panel, slide it toward the rear of the vehicle. Disengage the 5 claws of the front side of the instrument panel and remove the instrument panel.

14. REMOVE STARTER CUT RELAY

1. Remove the starter cut relay.

STARTER CUT RELAY (w/ Entry and Start System) > INSPECTION 1. INSPECT STARTER CUT RELAY





Below 1Ω (when battery voltage


3 - 5

10 kΩ or higher


STARTER CUT RELAY (w/ Entry and Start System) > INSTALLATION 1. INSTALL STARTER CUT RELAY

1. Install the starter cut relay.

2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER

1. Using a nipper, cut off both ends of the runner portion shown in the illustration (When installing a new one).

2. Engage the 5 claws at the upper side of the instrument panel.

3. Engage the claw and the 3 clips at the lower side of the instrument panel.

4. Install the instrument panel upper with the 2 <C> bolts and the 4 <B> screws.

Torque: 20 N*m 204 kgf*cm , 15 ft.*lbf for bolt

5. Connect the connectors.

6. Connect the passenger airbag connector and clamp.

3. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY

1. Engage the claw of the hinge portion in the horizontal direction to install the glove compartment door assembly.

NOTICE: Engage the claw in the horizontal direction, otherwise, installation failure caused by excessive play around the hinge portion will result.

2. Slightly deform the upper portion of the glove compartment door assembly to engage the stopper.

4. INSTALL SWITCH HOLE BASE

1. Disengage the 2 clips and 2 claws and install the switch hole base.

5. INSTALL FRONT PILLAR GARNISH RH


1. Remove the piece of cloth or nylon.


1. Insert the hook into the body hole. 2. Engage the clip and install the front speaker.

3. Connect the speaker connector.

3. Install the 3 antenna cord clamps.



1. Install a new special clip and the clip onto a new front pillar garnish. 2. Engage the 2 clips and the 2 claws and install the front pillar garnish.


1. Engage the 2 clips and the 2 claws and install the front pillar garnish.

6. INSTALL FRONT PILLAR GARNISH LH


1. Remove the piece of cloth or nylon.


1. Insert the hook into the body hole. 2. Engage the clip and install the front speaker.

3. Connect the speaker connector.

3. Install the 4 wire harness clamps.


1. Install a new special clip and the clip onto a new front pillar garnish. 2. Engage the 2 clips and the 2 claws and install the front pillar garnish.


1. Engage the 2 clips and the 2 claws and install the front pillar garnish.

7. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH

1. Install the front door opening trim weatherstrip.

8. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH

1. Install the front door opening trim weatherstrip.

9. INSTALL INSTRUMENT CLUSTER FINISH PANEL

1. Fit the 3 A claws of the instrument cluster finish panel into the upper instrument cluster finish panel center.

2. Engage the 4 claws and 5 clips and install the instrument cluster finish panel.

10. INSTALL COMBINATION METER ASSEMBLY

1. Install the combination meter assembly with the 2 screws.

2. Connect the 2 connectors.

11. INSTALL INSTRUMENT CLUSTER FINISH PANEL

1. Fit the 3 A claws of the instrument cluster finish panel into the upper instrument cluster finish panel center.

2. Engage the 4 claws and 5 clips and install the instrument cluster finish panel.

12. INSTALL INSTRUMENT PANEL FINISH PANEL END RH

1. with CD player

1. Connect the connector. 2. Engage the 4 claws and 3 clips and install the instrument panel finish

panel end RH.

2. Except CD player


panel end RH.

13. INSTALL INSTRUMENT PANEL FINISH PANEL END LH

1. with CD player


panel end LH.

2. Except CD player


panel end LH.

14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque:

5.4 N*m 55 kgf*cm , 48 in.*lbf 15. CHECK SRS WARNING LIGHT ()

ACC RELAY (w/ Entry and Start System) > COMPONENTS

1 / 1

ACC RELAY (w/ Entry and Start System) > REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE INSTRUMENT PANEL BOX

1. Open the instrument panel box.

2. Pull the hinge side of the instrument panel box out horizontally with the instrument panel open and disengage the 2 hinges.

3. Remove the stopper of the instrument panel box from the cutout of the instrument panel lower and remove the instrument panel box.

3. REMOVE ACC RELAY

1. Remove the ACC relay.

ACC RELAY (w/ Entry and Start System) > INSPECTION 1. INSPECT ACC RELAY





Below 1 Ω 3 - 4 10 kΩ or higher

(when battery

voltage applied to terminals 1 and 2) Below 1 Ω (when

battery voltage applied to terminals

1 and 2) 3 - 5

10 kΩ or higher


ACC RELAY (w/ Entry and Start

System) > INSTALLATION 1. INSTALL ACC RELAY

1. Install the ACC relay.

2. INSTALL INSTRUMENT PANEL BOX

1. Insert the stopper of the instrument panel box from the cutout of the instrument panel lower.

2. Engage the 2 hinges with the instrument panel open.

3. Close the instrument panel box.


5.4 N*m 55 kgf*cm , 48 in.*lbf

ACC CUT RELAY (w/o Entry and Start System) > COMPONENTS

1 / 1

ACC CUT RELAY (w/o Entry and Start System) > INSPECTION

1. INSPECT ACC CUT RELAY



Standard: Tester


Below 1 Ω

3 - 4 10 kΩ or higher (when battery

voltage to terminals 1 and 2)

Below 1 Ω (when battery voltage to terminals 1 and 2) 3 - 5

10 kΩ or higher


INTEGRATION RELAY > COMPONENTS

1 / 1

INTEGRATION RELAY > INSPECTION

1. INSPECT INTEGRATION RELAY

1. Inspect AM2 (15A) fuse.

1. Disconnect the fuse. Using an ohmmeter, measure the resistance of the fuse.


Connection Specified condition

1 - 2 Below 1 Ω

2. Inspect IG2 relay.



Connection Specified condition

B1 - C1 Below 1 Ω

Below 1 Ω (Apply battery

voltage between terminals B2 and

B3)

B1 - B4

10 kΩ or higher Below 1 Ω

(Apply battery voltage between terminals B2 and

B3) B4 - C1

10 kΩ or higher NOTICE:

While using the battery for inspections, do not bring the positive and negative tester probes too close to each other as a short circuit may occur.

IGNITION RELAY > COMPONENTS

1 / 1

IGNITION RELAY > INSPECTION

1. INSPECT IGNITION RELAY





Below 1 Ω (when battery voltage


3 - 5

10 kΩ or higher


ENGINE SWITCH (w/ Entry and Start System) > COMPONENTS

5 / 5

ENGINE SWITCH (w/ Entry and Start System) > INSPECTION

1. INSPECT ENGINE SWITCH

1. Measure the resistance of the switch.


Connection Switch

Position Specified Condition

7 (SS1) - 5 (GND) Released 10 kΩ or

higher 2 (SS2) - 5

(GND) Released 10 kΩ or higher



If the result is not as specified, replace the engine switch.

IGNITION SWITCH (w/o Entry and Start System) > COMPONENTS

IGNITION SWITCH (w/o Entry and Start System) > REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE STEERING COLUMN COVER

1. Turn the steering wheel to the right and remove the screw indicated in the illustration.

2. Turn the steering wheel to the left and remove the screw indicated in the illustration.

3. Remove the screw indicated in the illustration and remove the steering column cover.

3. REMOVE IGNITION OR STARTER SWITCH ASSEMBLY


2. Disengage the 2 claws and remove the ignition or starter switch assembly.

IGNITION SWITCH (w/o Entry and Start System) > INSPECTION 1. INSPECT IGNITION OR STARTER SWITCH ASSEMBLY




Condition Tester Connection Standard

LOCK Between all terminals

10 kΩ or higher

ACC 2-4 Below 1 Ω

1-2-4 ON

5-6 Below 1

Ω

1-3-4 START

5-6-7 Below 1

Ω

IGNITION SWITCH (w/o Entry and

Start System) > INSTALLATION 1. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY

1. Engage the 2 claws and install the ignition or starter switch assembly.


2. INSTALL STEERING COLUMN COVER

1. Install the screw indicated in the illustration.

2. Turn the steering wheel to the left and install the screw indicated in the illustration.

3. Turn the steering wheel to the right, and install the screw indicated in the illustration.


5.4 N*m 55 kgf*cm , 48 in.*lbf

1kr fe starting starting motor

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