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Refer to Engine Controls Schematics MAF, Secondary Air Injection Pump Bypass Solenoid, IAC and Secondary AIR Pump . Circuit Description The AIR pump is used on this vehicle to lower tail pipe emissions on start-up. The powertrain control module (PCM) grounds the AIR pump relay control circuit, which energizes the AIR pump. The PCM also grounds the AIR solenoid valve control circuit, which energizes the AIR solenoid valve. The AIR solenoid valve opens allowing manifold vacuum to open the AIR control valves. The PCM enables both control circuits when AIR system operation is desired. When the AIR system is active, the AIR pump forces fresh air into the exhaust stream in order to accelerate catalyst operation. The AIR control valves replace the conventional check valves. When the AIR system is inactive, the AIR control valves prevent air flow in either direction. DTC P0412 applies to the AIR solenoid control circuit. DTC P0418 applies to the AIR pump relay control circuit. DTC P0410 sets if an air flow problem is detected. The PCM will run two tests using the heated oxygen sensor (HO2S) voltage to diagnose the AIR system. Both tests have two parts. The passive test is performed during regular AIR pump operation. The passive test consists of the following: Passive Test Part 1 When the AIR system is enabled, the PCM monitors the HO2S voltage. If the HO2S voltage goes below a threshold, the PCM interprets this as an indication that the AIR system is operational. Passive Test Part 2 When the AIR system is disabled, the PCM monitors the HO2S voltage. The HO2S voltage should increase above a threshold and switch normally. If both of these tests indicate a pass, no further action is taken. If one of the above tests failed or is inconclusive, the diagnostic will proceed to test two. The active test is performed specifically for diagnostic purposes. Test two consists of the following: Active Test Part 1 During this test the PCM turns the AIR system on during closed loop operation. When the AIR system is activated, the PCM monitors the HO2S voltage. If the AIR system is operating properly, the HO2S voltage should go below a predetermined threshold. Active Test Part 2 The PCM turns the AIR system off. The HO2S voltage should return to above a rich threshold.

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AIR INDUCTION SYSTEM CARBURETED Air Intake System The air intake system used on carbureted vehicles supplies fresh, filtered, temperature-controlled air to the carburetor. System consists of an air cleaner, air intake pipe, carburetor, intake manifold and intake air control system. The intake air control system maintains a uniform air temperature inside the air cleaner. Carburetor receives fresh air, controlled within a narrow temperature range, regardless of outside temperature. Carburetor Carburetor is a 2-barrel downdraft fixed venturi type. Carburetor consists of 3 layers, a choke valve and air horn make up the top layer; the venturi, float chamber, accelerator pump, actuator, and choke housing make up the middle layer; and the primary and secondary throttle valves, secondary diaphragm, and pilot screw are part of the throttle body, or bottom layer of the carburetor. FUEL INJECTION

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ISSUE On some 2002-04 MY X-TYPE vehicles within the above VIN range, customers may have concerns with the vehicle interior fogging or the climate control cooling the vehicle slowly. The concern may be caused by the air inlet blend door being loose on the actuator shaft. ACTION In case of a customer complaint of the above condition on a 2002-04 MY X-TYPE vehicle within the above VIN range, first test the operation of the air inlet blend door. Set the fan speed to MAX and manually de-select the recirc button, there should be an audible difference in the climate control temperature motor noise. If the volume stays the same then the air inlet blend door is suspect. To rectify follow the workshop procedure outlined below. WORKSHOP PROCEDURE 1. 2. 3. 4. 5. 6. Open door. Turn ignition ‘ON’. Operate front seat fully rearward for access. The air recirculation switch should be in the fresh air mode. Turn ignition ‘OFF’. Remove the glove compartment hinge retaining screws (Fig. 1 ).7. Remove the glove compartment retaining screws (Fig. 2 ). 8. Disconnect the glove compartment lamp electrical connector (Fig. 3 ). 9. Remove the glove compartment. 10. Disconnect the air inlet blend door actuator electrical connector, undo and remove the climate control upper front stepper motor securing screws and displace the climate control stepper motor and reposition to gain working access (Fig. 4 ).

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In case of a customer complaint of the above condition on a 2002-04 MY X-TYPE vehicle within the above VIN range, first test the operation of the air inlet blend door. Set the fan speed to MAX and manually de-select the recirc button, there should be an audible difference in the climate control temperature motor noise. If the volume stays the same then the air inlet blend door is suspect. To rectify follow the workshop procedure outlined below. WORKSHOP PROCEDURE 1. Open door. 2. Turn ignition ‘ON’. 3. Operate front seat fully rearward for access. 4. The air recirculation switch should be in the fresh air mode. 5. Turn ignition ‘OFF’. 6. Remove the glove compartment hinge retaining screws (Illustration 1). 7. Remove the glove compartment retaining screws (Illustration 2). 8. Disconnect the glove compartment lamp electrical connector (Illustration 3). 9. Remove the glove compartment. 10. Disconnect the air inlet blend door actuator electrical connector, undo and remove the climate control upper front stepper motor securing screws and displace the climate control stepper motor and reposition to gain working access (Illustration 4). 11. Remove the air inlet blend door actuator securing screws (Illustration 5). 12. Displace and remove actuator. 13. On all vehicles, align the actuator shaft as follows: Connect the air inlet blend door actuator to the electrical connector, and switch the ignition ‘ON’. By a combination of operating the air recirculation button ON/OFF and disconnecting the electrical connector at the correct time set the shaft to the correct position. The flat opposite the curved face should be set nearest to and parallel with the line on the actuator body (Illustration 6). Note: A DTC will be stored during the alignment procedure since the open circuit will be detected. 14. Turn ignition ‘OFF’. 15. Ensure the air inlet blend door is in the fresh air position.

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Inflation and Deflation of the Air Suspension System WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. WARNING: Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. 1. Turn the air suspension switch on. 2. Turn the ignition switch to the RUN position. 3. Connect NGS Tester to the data link connector (DLC). 4. Select Air Suspension Control Module under Active Command Mode: ? VENT FRNT to deflate the front down. ? LIFT FRNT to inflate the front up. ? VENT REAR to deflate the rear down. ? LIFT REAR to inflate the rear up. Calibration Front Ride Height Resetting — Clear B2140 DTC 1. Turn the ignition key OFF and turn it back to RUN; exit the vehicle, close all doors and allow the system to vent the vehicle down to kneel height (approximately 30 seconds). 2. Connect New Generation STAR (NGS) Tester to the data link connector (DLC). 3. Select the proper vehicle year, model and engine type. 4. Select 4WAS-AIR SUSP/EVO (4×2 and 4×4) module. 5. Select “Parameter Reset Command (Clear Ride Height) under Active Command Modes” menu, trigger through the warning messages and reset (trigger from OFF to ON): ? NGS version 10.0 — “Front” and “Rear.” ? NGS version 11.0+ — “Front CLR.” 6. Back out the torsion bar adjustment bolt (approximately 40 mm from the bolt head to the bottom surface of the torsion bar adjuster). 7. Deflate the front air shocks by using the NGS “Vent Front” command in “Air Suspension Control” menu (should take about 30 seconds), and jounce the front of the vehicle to fully lower the front of the vehicle. 8. Adjust and measure the vehicle ride height; refer to Section 204-01B. 9. NOTE: Do not save rear ride heights. The air suspension control module has precalibrated values already stored. Refer to Rear Ride Height Mechanical Resetting. Select the “Save Calibration Values (Store Ride Height)” NGS command to calibrate the air suspension control module. Trigger through the warning message(s) and save “FRONT” (trigger from OFF to ON).