Accent 1.5L 2005

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ACCENT(LC) > 2005 > G 1.5 SOHC > General Information
General Information > General Information > General Information

IDENTIFICATION NUMBER
VEHICLE IDENTIFICATION NUMBER LOCATION
IDENTIFICATION NUMBER DESCRIPTION

VEHICLE IDENTIFICATION NUMBER
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1. Geographic zone
- K : Korea
2. Manufacturer
- M : Hyundai motor company
3. Vehicle type
- H : Passenger
4. Vehicle line
- C : ACCENT
5. Model & Series
- F : STANDAD (L)
- G : DELUXE (GL)
- H : SUPER DELUXE (GLS)
6. Body type
- 3 : Sedan 3 - Door
- 4 : Sedan 4 - Door
7. Restraint system
- 3 : Drive side - Active belt and air bag
Passenger side - Active belt or passive belt
- 4 : Both side - Active belt and air bag
- 5 : Depowered - Air bag
8. Engine type
- C : Gas 1.6 DOHC
- G : Gas 1.5 SOHC
9. Driver side
- 1 ~ 9, X
10. Production year
- 3: 2003, 4 : 2004, 5 : 2005, 6 : 2006
11. Plant of production
- U : Ulsan (Korea)
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12. Vehicle production sequence number
- 000001 ~ 999999
PAINT CODE
CODE COLOR
NW Noble White
EB Ebony Black
CS Clean Silver
HL Hiphop Red
YA Potomac Blue
TI Tundra Green
UA Hof Gold
WS Technical Gray
ZG Mass Green
VS Celadon Blue
ENGINE IDENTIFICATION NUMBER
1. Engine fuel
- G : Gasoline
2. Engine range
- 4 : In line 4 cycle 4 cylinder
3. Engine development order
- E : Alpha engine
4. Engine capacity
- B : 1495 cc
- D : 1599 cc
5. Production year
- 3 : 2003, 4 : 2004, 5 : 2005, 6 : 2006
6. Engine production sequence number
- 000001 ~ 999999
TRANSMISSION IDENTIFICATION NUMBER
MANUAL
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1. Model
- H : M5AF3
2. Production year
- 2 : 2002, 3 : 2003, 4 : 2004
- 5 : 2005, 6 : 2006, 7 : 2007
3. Gear ratio
- 2073 : 3.650
4. Transmission production sequence number
- 000001 ~ 999999
AUTOMATIC
1. Model
- T : A4AF3
2. Production year
- 2 : 2002, 3 : 2003, 4 : 2004
- 5 : 2005, 6 : 2006, 7 : 2007
3. Gear ratio
- K : 3.443
- L : 3.656
- N : 4.041
4. Detailad classification
- AD : 1.5 DOHC
- ID : 1.6 DOHC
5. Spare
6. Transmission production sequence number
- 000000 ~ 999999
WARNING / CAUTION LABEL LOCATIONS
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AIR BAG WARNING / CAUTION LABEL

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AIR BAG WARNING / CAUTION LABEL (CONT'D)

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WARNING / CAUTION LABEL (CON'T)

A : SRS INFORMATION
WARNING
Death or serious injury can occur.
• Children 12 and under can occur.
• The back seat is the safest place for children.
• Never put a rear-facing child seat in the front.
• Sit as far back as possible from the airbag.
• Alway use seat belts and child restraints.
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B : WARNING
SEE OWNER'S MANUAL
This car is equipped a side airbag for each front seat.
• Do not use any accessory seat covers.
• Use of other seat covers could reduce the effect of the system.
• Do not install any accessories on the side or rear the side airbag.
• Do not use excessive force on the side of the seal.
• For further information, see the owner's manual.
C : CAUTION
AIRBAG ESPE UNIT
Detach connector before unmounting. Assemble strictly according to manual instructions.
D : PASSENGER MODULE CAUTION
CAUTION
Don't open, remove or transfer to another vehicle.
Risk of malfunction and bodily injury!
This unit is to be installed and/or dismantled by trained personnel only. This item contains an explosive to be
installed igniter.
E : SUPPLEMENTAL RESTRAINT SYSTEM

(AIRBAG) INFORMATION
• The airbag is a Supplement Restraint System (SRS).
You must always wear the seat belts.
• The airbag system condition is normal when the "SRS" lamp in the cluster flashes approximately 6 times after
the ignition key is turned on and then goes off.
• If any of the following condition occur, the system must be serviced.
• "SRS" lamp dose not light up when the key is turned on.
• "SRS" lamp stays lit or flashes continuously.
• The airbag has inflated.
• The airbag system must be inspected by an authorized dealer ten years after the vehicle manufacture date
shown on the certification label, located on left front door opening area.
• WARNING
Failure to the above instructions may result injury to you or other occupants in the vehicle.
• See the "SRS" section in owner's Manual for more information about airbags.
EMISSION CONTROL LABEL

Emission Grop Identification
EXAMPLE :
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B:
1. Model Year
- 4 : 2004
2. Manufacturer Subcode
- HYX : HYUNDAI MOTOR
3. Family Type
- V : Passenger car
4. Displacement
5. Sequence Characters.
C:
1. Model Year
- 4 : 2004
2. Manufacturer Subcode
- HYX : HYUNDAI MOTOR
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3. Family Type
- R : EVAP/ORVR
4. Canister Work Capacity
5. Sequence Characters
LIFT AND SUPPORT POINT
When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed,
place additional weight in the luggage area before hoisting . When substatial weight is removed from the rear of the
vehicle the, center of gravity may change and cam cause the vehicle to tip forward on the hoist.
• Since each tire/wheel assembly weights approximately 30lbs(14kg), placing the front wheels in the luggage area
can assist with weight distribution.
• Use the same support points to support the vehicle on safely stands.
1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimerers) and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.
TOWING
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If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is
very dangerous.
- The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.
- The tow truck uses two pivoting arms that go under the tires (front or rear) and lift them off the ground. The other
two wheels remain on the ground.
If the vehicle cannot be transported by flat-bed, if should be towed with the front wheels off the ground. If due to
damage, the vehicle must be toward with the front wheels on the ground, do not following :
Manual Transmission
• Release the parking brake.
• Shift the transmission to neutral.
Automatic Transmission
• Release the parking brake.
• Start the engine.
• Shift to [D] position, then [N] position.
• Turn off the engine.
• Improper towing preparation will damage the transmission. Follow the above procedure exactly.
Follow the above procedure exactly. If you cannot shift the transmission or start the engine (automatic
transmission), your vehicle must be transported on a flat-bed.
• It is best to tow vehicle no farther than 19miles (30km), and keep the speed below 30mph (50km/h).
• Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not
designed to support the vehicle's weight.
FRONT :
REAR :
TIGHTENING TORQUE TABLE OF STANDARD PARTS

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Bolt nominal Torque Nm (kg.cm, lb.ft)

Pitch (mm)
diameter (mm) Head Mark 4 Head Mark 7
M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

M6 1.0 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0)
M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11) 20 ~ 25 (200 ~ 250, 14.5 ~ 18.0)
M10 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36)
M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)
M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61) 120 ~ 140 (1,200 ~ 1,400, 85 ~ 100)
180 ~ 210 (1,800 ~ 2,100, 130 ~
M16 1.5 110 ~ 130 (1,100 ~ 1,300, 80 ~ 94)
150)
160 ~ 180 (1,600 ~ 1,800, 116 ~ 260 ~ 300 (2,600 ~ 3,000, 190 ~
M18 1.5
130) 215)
220 ~ 250 (2,200 ~ 2,500, 160 ~ 360 ~ 420 (3,600 ~ 4,200, 260 ~
M20 1.5
180) 300)
290 ~ 330 (2,900 ~ 3,300, 210 ~ 480 ~ 550 (4,800 ~ 5,500, 350 ~
M22 1.5
240) 400)
360 ~ 420 (3,600 ~ 4,200, 260 ~ 610 ~ 700 (6,100 ~ 7,000, 440 ~
M24 1.5
300) 505)
1. The torques shown in the table are standard values under the following conditions :
• Nuts and bolts are made of galvanized steel bar.
• Galvanized plain steel washers are inserted.
• All nuts, bolts, and plain washers are dry.
2. The torques shown in the table are not applicable :
• When spring washers, toothed washers and the like are inserted.
• If plastic parts are fastened.
• If self - tapping screws or self - locking nuts are used.
• If threads and surfaces are coated with oil.
3. If you reduce the torques in the table to the percentage inddcated below, under the following conditions, if will
be the standard value.
• If spring washers are used. : 85%
• If threads and braring sufaces are stained with oil : 85%
LUBRICANTS
RECOMMENDED LUBRICANTS
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Parts OIL & GREASE STANDARD
Hot Climate : SAE 20W -40, 20W-50
(ABOVE 32°F For 0°C)
API SH, SG or Normal Climate : SAE 10W-30, 10W-40,
Engine oil
ABOVE 10W-50 (ABOVE -10°C For -23°C)
Cold Climate : SAE 5W-30, 5W-30, 5W-
40 (BELOW100° FoR 38°C)
Manual HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4)
Transaxle
Auto DIAMOND ATF SP-III, SK ATF SP-111
Power Steering PSF-3
Brake Fluid DOT 3, DOT 4 or equivalent
Coolant Ethylene glycol base for aluminium radiator.
Transaxle linkage, parking brake cable
mechanism, hood lock and hook, door latch,
Multipurpose grease NLGI grade #2
seat adjust, tailgate latch, door hinges,
tailgate hinges
Always use Genuine Hyundai parts and recommedended fluid.

Using any other type of parts and fluid can cause serious damage of the vehicle.
LUBRICANTS CAPACITIES
Capacities [liter (U.S. qus.,
Description lmp.qts.)]
1.5/1.6
Oil pan 3.0 (3.17, 2.64)
Engine oil Oil filter 0.3 (0.32, 0.26)
Total 3.3 (3.49, 2.90)
Cooling system 6.5 (6.87, 5.72)
Manual transaxle 2.15 (2.3, 1.86)
Automatic transaxle 6.1 (6.45, 5.37)
Power steering 0.9 (0.95, 0.79)
SELECTION OF ENGINE OIL

Recommended SAE viscosity grades :
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For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirements of the API classification.
2. Have the proper SAE grade number for expected ambient temperature range.
GENERAL SERVICE INFORMATION
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas before starting work.
The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine
compartment to prevent the hood from falling and possibly causing injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is
firmly latched before driving the vehicle.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT
Be sure that all necessary tools and measuring equipment are available before starting work.
SPECIAL TOOLS
Use special tools when they are required.
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REMOVAL OF PARTS
First find the cause of the problem and then determine whether removal or disassembly before starting the job.
DISASSEMBLY
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled
in a way that will not affect their performance or external appearance.
1. Inspection of parts
Each part, when removed, should be carefully inspected for malfunction, deformation, damage, and other
problems.
2. Arrangement of parts
All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify the parts to be replaced from those that will be used again.
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3. Cleaning parts for reuse
All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.
PARTS
When replacing parts, use HYUNDAI genuine parts.
REPLACEMENT
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
Depending on their location.

7. Sealant should be applied to gaskets.
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8. Oil should be applied to the moving components of parts.
9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc.) before assembly.
ADJUSTMENT
Use gauges and testers to correctly adjust the parts to standard values.
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wires when disconnecting connectors.
3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully. Be careful not to drop them against other parts.
RUBBER PARTS AND TUBES

Always prevent gasoline or from touching rubber parts or tubing.
MEASURING BODY DIMENSIONS

1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimensioners and actualmeasurement dimensions are used in this
manual.
PROJECTED DIMENSIONS
1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and
are the reference dimensions used for body alterations.
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2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as
the difference value in height of the two surface.
MEASURING ACTUAL DIMENSIONS

1. These dimensions indicate the actual linear distance between measurement points, and are used as the reference
dimensions when a tracking gauge is used for measurement.
2. First adjust both probes to the same length (A=A') before measurement.
Check the probes and gauge itself to make sure there is no free
play.
MEASUREMENT POINT
Measurements should be taken at the center of the hole.
CHECKING CABLES AND WIRES

1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounded parts firmly that there is complete continuity between their attaching bolt(s) and the vehicle's
body.
7. Check for incorrect wiring.
8. Check that the wiring is clamped to prevent contact with sharp corners of the vehicle body or hot parts (exhaust
manifold, etc.).
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9. Check that the wiring is clamped firmy to provide enough clearance from the fan pulley, fan belt and other
rotating or moving parts.
10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle
body and the engine.
CHECK FUSES
A blade type fuse test leads provided to allow checking the fuse itself without removing it from the fuse box. The
fuse is good if the test lamp lights up when one lead is connected to the test leads (one at a time) and the other lead
is grounded. (Turn on the ignition switch so that the fuse circuit becomes operative)
SERVICING THE ELECTRICAL SYSTEM

1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground
cable.
In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble
code retained by the computer will be cleared. Therefore, if necessary, read the diagnostic before
removing the battery cable.
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2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the
engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine
vibrations to cause the harness to come into contact with any of the surrounding parts and then secure the harness
by using a clamp.
3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness
with tape or something similar in order to protect it from damage.
4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
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6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service
operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts beforehand.
7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
8. When disconnecting a connector, be sure to grip only the connector, not the wires.
9. Disconnect connector which have catches by pressing in the direction of the arrows shown in the illustration.
10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
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11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the
harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until
contacts the terminal, being careful not to damage the insulation of the wires.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration,
and determine the appropriate wire size.
Nominal Permissible current
SAE gauge No.
size In engine compartment Other areas
0.3mm² AWG 22 - 5A
0.5mm² AWG 20 7A 13A
0.85mm² AWG 18 9A 17A
1.25mm² AWG 16 12A 22A
2.0mm² AWG 14 16A 30A
3.0mm² AWG 12 21A 40A
5.0mm² AWG 10 31A 54A
PRECAUTIONS FOR CATALYTIC CONVERTER
If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To
prevent this observe the following precations and explain them to your customer.
1. Use only unleaded gasoline.
2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than
10minutes and idle speed for more than 20 minutes.
3. Avoid start-jump tests. Do start-jumps only when absolutely necessary. Perform this test as rapidly as possible
and, while testing, never race the engine.
4. Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly as
possible.
5. Avoid coasting with the ignition turned off and during prolonged braking.
6. Do not dispose of used catalytic converter with parts contaminated by gasoline or oil.
BODY DIMENSION
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ACCENT(LC) > 2005 > G 1.5 SOHC > Automatic Transaxle System
Automatic Transaxle System > General Information > Special Service Tools
SPECIAL TOOLS (A/T)
Tool (Number and
Illustration Use
Name)
09452-21001 Measurement of the oil pressure
Oil pressure gauge adapter (Use with 092452-21002, 09452-
21500)

Oil pressure gauge adapter (Use with 09452-21500 and 09452-
21001)

Oil pressure gauge (Use with 09452-21001 and 09452-
21002)
J28467-B Removal and installation of transaxle

Engine support fixtrue assembly
J28467-125 Use with J28467-B

Engine support adapters
SPECIAL TOOLS (M/T)

Tool (Number and
Illustration Use
Name)
J28467-B Removal and installation of transaxle
Engine support fixture assembly
J28467-125 Use with J28467-B

Engine support adapters
Automatic Transaxle System > General Information > Troubleshooting

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TROUBLESHOOTING (M/T)
Symptom Probable cause Remedy
Vibration, noise Loose or damaged transaxle and engine mounts Tighten or replace mounts
Inadequate shaft end play Correct end play
Worn or damaged gears Replace gears
Inadequate grade of oil Replace with specified oil
Low oil level Replenish
Inadequate engine idle speed Adjust idle speed
Oil leakage Broken or damaged, oil seal or O-ring Replace control cable
Hard shift Faulty control cable Replace control cable
Poor contact or wear of synchronizer ring and Correct or replace
gear cone
Weakened synchronizer spring Replace synchronizer spring
Inadequate grade of oil Replace with specified oil
Jumps out of gear Worn gear shift fork or broken poppet spring Replace shift fork or poppet spring
Synchronizer hub-to-sleeve spline clearance too Replace synchronizer hub and sleeve
large
PROBLEM CHART (M/T)

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Automatic Transaxle System > General Information > Specifications

SPECIFICATIONS (A/T)
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Item A4AF3
Torque converter type D3-element, 1-stage, 2-phase type
Transaxle type D4-speed forward, 1-speed reverse
Engine displacement 1.5SOHC 1.6DOHC
Gear ratio 1st 2.846 ←
2nd 1.581 ←
3rd 1.000 ←
4th 0.685 ←
Reverse 2.176 ←
Final gear ratio 3.656 4.041
End play Front clutch snap ring 0.5±0.1
(mm) Rear clutch snap ring 0.8±0.1
End clutch snap ring 0.5±0.1
Low and reverse brake snap
0.675~0.987
ring
TIGHTENING TORUQE (A/T)

Item N·m kg·cm lb·ft
Shift lever mounting bolt 12-15 120-150 8-11
Starter motor mounting bolt 27-34 270-340 19-25
Shift lever cam rod nut 14-20 140-200 10-14
Knob and lever assembly More than 2 More than 20 More than 1.4
Bell housing cover to engine 8-10 80-100 6-7
Transaxle mounting bracket to
30-40 300-400 21-28
body frame
Transaxle mounting insulator bolt 90-110 900-1100 63-77
Front roll stopper to subframe 30-40 300-400 21-28
Front roll stopper insulator bolt 45-60 450-600 33-44
Rear roll stopper to subframe bolt 30-40 300-400 21-28
Rear roll stopper insulator bolt 45-60 450-600 33-44
Kick down servo lock nut 15-22 150-220 11-16
Lever indicator panel More than 15 More than 150 More than 11
Oil drain plug, filler plug 30-35 300-350 22-25
Transaxle range switch 10-12 100-120 7-9
LUBRICANT
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Items Specified lubricant Quantity
DIAMOND ATF SP-III, SK ATF
Transaxle fluid Lit. (U.S. qts., lmp.qts.) 6.1 (6.3, 5.3)
SP-III
Drive shaft oil seal lip Automatic transaxle fluid As required
Sliding part of bushing Chassis grease SAE J310, NLGI No.0 As required
Multipurpose grease SAE J310, NLGI
Selector lever sliding portion As required
No.2
Oil pan gasket LOCTITE 5460 As required
SPECIFICATIONS (M/T)
Model M5AF3
Type Forward 5 speed, reverse 1 speed
Engine displacement 1.5SOHC 1.6DOHC
Gear ratio First 3.615 3.615
Second 2.053 2.053
Third 1.370 1.370
Fourth 0.971 1.031
Fifth 0.825 0.825
Reverse 3.250 3.250
Final gear ratio 3.650 3.842
HYUNDAI GENUINE PARTS MTF
Transaxle fluid
75W/90
Capacity (Lit., u.s.qts, Imp.qts) 2.15 (2.27, 1.89)
SERVICE SPECIFICATIONS (M/T)

Item End play
Input shaft rear bearing
0.01L - 0.09L
end play
Output shaft bearing
0.05T - 0.10T
end play
Differential bearing end
0.15T - 0.20T
play
Differential pinion end
0.025L - 0.15L
play
Input shaft front bearing
0.01L - 0.12L
end play
TIGHTENING TORQUE (M/T)

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Item N·m Kg·cm lb·ft
Shift lever mounting bolt 9-14 90-140 6-10
Clutch release cylinder 15-22 150-220 11-16
Control cable bracket 12-15 120-150 8-11
Front roll stopper to sub
30-40 300-400 21-28
frame
Front roll stopper insulator
45-60 450-600 33-44
bolt
Rear roll stopper to
30-40 300-400 21-28
subframe bolt
Rear roll stopper insulator
45-60 450-600 33-44
bolt
Transaxle mounting bracket
30-40 300-400 21-28
to body frame
Transaxle mounting
90-110 900-1100 63-77
insulator bolt
LUBRICANT (M/T)
Items Specified lubricant Quantity
Clutch release fork
CASMOLY L9508 1g
shaft&bushing
Automatic Transaxle System > Automatic Transaxle System > Flow Diagram
AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT
NEUTRAL & PARK
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DRIVE (FIRST)
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DRIVE (SECOND)
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DRIVE (THIRD)
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DRIVE (FOURTH)
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REVERSE
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HYDRAULIC CONTROL SYSTEM

MANUAL VALVE
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Operation Shift control solenoid
valve
Position A B C
1st gear ON ON OFF
2nd gear OFF ON OFF
3rd gear OFF OFF ON
4th gear ON OFF ON
Items A4AF2 A4AF3

Pressure Control for PCV + PCSV PCV-A + PCSV-A
SA, E/C PCV N-D V/v 1-2Shift V/v PCV-A, 1-2Shift V/v
Pressure Control for PCV + PCSV PCV-B + Another Sol. V/v (PCSV-
R/C B)
PCV N-D V/v RCE V/v PCV-B, RCE V/v (with accumulator)
Changed points :
- N-D valve has been eliminated.
- PCSV-B has been added for Rear clutch pressure control independently.
- Mechanical accumulator has been adopted.
- E/C release control : PCV-A, Switching of SA, E/C :CSV
- Function
Switching the pressure of E/C and SA.
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- 2nd. Gear
• The 2nd. pressure is supplied to SA through CSV.

• SCSV-C is OFF as well as 1st. gear.
- 2nd.→3rd. gear
• SCSV-C maintains OFF as well as 2nd gear.
• The E/C pressure from shift control valve is intercepted at the E/C valve during up-shifting from 2nd to 3rd
gear.
• SA pressure is supplied from 1-2 shift valve, but the front clutch and SR pressure is also supplied from the 2-
3/4-3 shift valve, so the both SR and SA pressure will be set off.
- 3rd. gear
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• SCSV-C is changed from OFF to ON.
• The E/C pressure is supplied from 1-2 shift valve at the CSV after finishing the up-shifting from 2nd to 3rd
gear.
• SA pressure is supplied from shift control valve, but the front clutch and SR pressure is also supplied from the
2-3/4-3 shift valve, so the both SR and SA pressure will be set off.
1. Operating elements
Speed R/C E/C K/D
4th. - O O
2nd. O - O
2. Controls
A. R/C engaging duty control
B. E/C releasing duty control
C. Continuous switching to SA
3. Description
A. R/C engaging duty control
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B. E/C releasing duty control
4→2 Skip shift only (SCSV-C ON)
When releasing the E/C clutch pressure, it is controlled by duty of PCSV-A only in case of 4→2 skip shift.
C. Continuous switching to SA
- From (SCV) to SA through (CSV)
1. TCM fail when drive with 1st or 2nd speed.
Speed F/C R/C E/C K/D
1st. O
2nd. O O
Fail O O
- F/C, SR : from 2-3/4-3 shift valve

- R/C : from PCV-B
- SA : from 1-2 shift valve
2. TCM fail when drive with 1st or 2nd speed.

Speed F/C R/C E/C K/D
1st. O
2nd. O O
Fail O O O
Page 23 of 116
- R/C, E/C, SA : Interlock
• SA : Servo Apply pressure

• F/C : Front Clutch pressure
• R/C : Rear Clutch pressure
• K/D : Kick Down
• SCV : Shift Control Valve
• CSV : Control Switch Valve
• PCSV : Pressure Control Solenoid Valve
• SCSV : Shift Control Solenoid Valve
• PCV : Pressure Control Valve
• RCEV : Rear Clutch Exhaust Valve
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > General
Information
GENERAL INFORMATION (A4AF3)
Automatic transaxle overhaul section has been separated from the shop manual.
A4AF3 overhaul section was included in the overhaul manual.
SELECTION OF SHIM
Page 24 of 116
Code Code
O.D I.D Thickness O.D I.D Thickness
No. No.
70 55.7 1.4 48.1 34.4 - #4
70 55.7 1.8 40 21 2.4 #5
#1
70 55.7 2.2 42.6 28 2.5 #6
70 55.7 2.6 54 38.7 1.6 #7
70 55.7 1.8 #2 52 36.4 2.8 #8
48.9 37 1.0 41 28 2.0 #9
48.9 37 1.2 39 28 1.2 #10
48.9 37 1.4 38 22.2 - #11
48.9 37 1.6 52 36.4 2.8 #12
#3
48.9 37 1.8 58 44 5.0 #13
48.9 37 2.0
48.9 37 2.2
48.9 37 2.4
Unit : mm
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Components and
Components Location
AUTOMATIC TRANSAXLE
COMPONENTS
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COMPONENTS (1)
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COMPONENTS (2)
Page 27 of 116
COMPONENTS (3)
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COMPONENTS (4)
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COMPONENTS (5)
Page 30 of 116
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Repair
procedures
REMOVAL
Page 31 of 116
1. Remove the battery terminal and the battery.
2. Removal the air cleaner.
3. Remove the transaxle range switch connector.

Page 32 of 116
4. Remove the solenoid valve connector and the oil temperature sensor connector.
5. Remove the cotter pin of the control cable.
6. Remove the oil filler tube.
7. Remove the clip of the control cable.
8. Remove the oil cooler hose.

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9. Remove the speedometer driven gear connector.
(speed sensor connector)
10. Remove the u-joint.
11. Remove the power steering return hose.

12. Remove the tire.
13. Remove the starter motor.
14. Remove the bolt for the upper connection of the engine and the transaxle.
Page 34 of 116
15. Remove the caliper after lifting up the vehicle.
16. Separate the tie rod end from the pin and nut.
17. Remove the oil drain plug and drain the oil.
18. Remove the transaxle side cover.
19. Remove the wheel speed sensor and the knuckle mounting bolt.
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20. Remove the drive shaft and the left side hub nut.
21. Install the special tool, the engine support fixture on the engine assembly.
22. Remove the transaxle mounting bracket after removing the hole cover and the mounting bolts.
23. Remove the front roll stopper.
24. Remove the rear roll stopper.

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25. Remove the front muffler.
26. Remove the bell housing cover. (Bolts : 5EA)
27. Remove the torque converter mounting plate bolts (3EA).
28. Remove the cylinder block plate bolt.
29. Install the jack for supporting transaxle.
30. Remove the lower mounting bolts (2EA) of the transaxle.

31. Remove the sub frame.
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32. Remove the transaxle.
INSTALLATION
1. Attach the torque converter on the transaxle side and mount the transaxle assembly onto the engine.
• If the torque converter is mounted on the engine first, the oil seal on the transaxle side may be damaged.
Therefore, be sure to first assemble the torque converter to the transaxle.
• When installing the roll stopper mounting bracket, be careful not to crush the insulator. If crushed, idle
vibration may occur.
2. Install the transaxle control cable and adjust as follows:

A. Move the shift lever and the transaxle range switch to the "N" position and install the control cable.
B. When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts to the
control cable.
C. Remove any free-play in the control cable by adjusting the nut and then check to see that the selected lever
moves smoothly.
D. Check to see that the control cable has been adjusted correctly.
Automatic Transaxle System > Automatic Transaxle System > Troubleshooting

TROUBLESHOOTING (A/T)
Page 38 of 116
ROAD TEST
Inspection procedure
Inspection
Procedure Conditions Operation Judgement value if there is an
item
abnormality
Ignition Overdrive switch • OD Overdrive Overdrive switch system
1 switch:ON • ON • OD-OFF switch
Engine stopped • OFF
Engine: Starting test with Starting should be Starting Starting impossible (will
2 Stopped lever in P or N possible possible or not crank)
range impossible
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Warming up Drive for 15 Gradually rises to Oil Codes - P0712, P0713
minutes or more so 70~110°C temperature Oil temperature sensor
that the automatic sensor system
3
transmission fluid
temperature
70~110°C
Engine:Idling Accelerator pedal • 2~18% TPS TPS system
Selector • Fully closed • Gradually rises
lever:N • Depressed from (1)
• Fully open • 80 ~ 100%
(for at least 2
seconds)
Selector lever Should be no Malfunction Engine stalling during
operation abnormal shifting when starting shifting
• N→D shift shocks.
Shocks when changing
• N→D shift Time lag should be
from N to D and long lag
within 2 seconds.
time
4
from N to R and long lag
time
from N to D, N to R and
long lag time
Engine:Idling Selector lever Should be no Driving Does not move forward
(Vehicle operation abnormal shifting impossible
stopped) • N→D shocks. Does not move (forward
Selector lever • N→R shift Time lag should be or reverse)
position:D within 2 seconds.
Engine:Idling Accelerator pedal • 75~90% Pressure Code P0745, P0775 -
(Vehicle • Fully closed • 100% control Pressure control solenoid
stopped) • Depressed solenoid valve system
Selector lever [Driving at valve
position:D 5km/h (3.1 (PCSV) - A,
mph)] B
Accelerator pedal •C Shift control Code P0750 - Shift

5 • Fully closed •1 solenoid control solenoid valve A
• Depressed valve A system
(SCSV-A)
Code P0755 - Shift
control solenoid valve B
system
Code P0760 - Shift
control solenoid valve C
system
Selector lever Engine •C Shift control Code P0750 - Shift
position:D • Idling (vehicle •1 solenoid control solenoid valve A
Overdrive:OFF stopped)
•1 Page 40 of 116
Overdrive:OFF stopped) •3 valve A system
• Driving at •2 (SCSV-A)
10km/h Shift control Code P0755 - Shift
• Driving at solenoid control solenoid valve B
constant speed valve B system
of 50km/h (SCSV-B)
(31mph) (20
Shift control Code P0760 - Shift
seconds or
solenoid control solenoid valve C
more)
valve C system
• Driving at
(SCSV-C)
constant speed
of 40km/h • OFF Kickdown Code P1709 -
(25mph) with • ON servo switch Kickdown servo switch
selector lever in • ON system
2 range • OFF
• Driving at
• 0km/h Vehicle Vehicle speed sensor
constant speed
• 10km/h speed sensor system
of 70km/h
(43mph) with • 50km/h
6
selector lever in • 40km/h
D range Pulse Code P0717 - Pulse
(3) 1,500~2,000rpm generator A generator A system
(PG-A)
Pulse Code P0722 - Pulse
(3) 1,500~2,000rpm generator B generator B system
(PG-B)
Torque Code P0743 - Torque
(3) 100~300rpm converter converter clutch solenoid
(5) 0~10rpm clutch
solenoid
Torque
(5) TCCS Duty : converter Code P0743 - Torque
40~85 clutch converter clutch solenoid
solenoid
For (3) and (5), Malfunction Poor acceleration
acceleration should while driving
be smooth with no
Vibration
abnormal vibration
Selector lever Engine (1) 3 speed gear Shift control Code P0750 - Shift
position:D (1) Driving at (1) 1,500~2,000rpm solenoid control solenoid valve A
Overdrive:ON constant speed of valve A system
50km/h (31mph) (SCSV-A)
(20 seconds or Shift control
more) Code P0755 - Shift
solenoid
control solenoid valve B
valve B
system
(SCSV-B)
7
Page 41 of 116
Shift control
7 Code P0760 - Shift
solenoid
control solenoid valve C
valve C
system
(SCSV-C)
Pulse
Code P0717 - Pulse
generator A
generator A system
(PG-A)
Pulse
Code P0722 - Pulse
generator B
generator B system
(PG-B)
Selector lever • Accelerate to For (1), (2) and (3) Malfunction Shocks and flare shifts
position:D 4th gear at TPS should match the when shifting
Overdrive:ON output of 1.5V specified output shaft
Displaced
(opening angle speed (vehicle All points
shifting points
30%) speed0, and there
• Slowly should be no Does not No fail-safe codes
decelerate to a abnormal shocks. shift
Code P0717 - Pulse
standstill For (4), (5) and (6), generator A system
• Accelerate to down shifting should
be made immediately Code P0722 - Pulse
4th gear at TPS generator B system
output of 2.5V after operation.
(opening angle Code P0750 - Shift
50%) contorl solenoid valve A
• At 50km/h system
(31mph) in 4th Code P0755 - Shift
gear, turn control solenoid valve B
8 overdrive OFF stystem
• At 50km/h Code P0760 - Shift
(31mph) in 3rd contorl solenoid valve C
gear, move system
selector lever to
2 range Code P0745, P0775 -
• At 20km/h Pressure control solenoid
(12mph) in 2 valve system
range, move Code P0731 - 1st gear
selector lever to incorrect ratio
L range.
Code P0732 - 2nd gear
incorrect ratio
Code P0733 - 3rd gear
incorrect ratio
Code P0734 - 4th gear
incorrect ratio
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES

DTC NO Diagnosis items Trouble area (Remedy) MIL
Fluid temperature sensor
P0711
-rationality check-
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P0711 • Fluid temperature sensor connector
-rationality check-
inspection
P0712 • Fluid temperature sensor inspection O
-short circuit-
• Fluid temperature sensor wiring harness
Fluid temperature sensor inspection
P0713
-open circuit-
Pulse generator A • Check the pulse generator A and pulse
P0717 -open circuit- generator B
• Check the vehicle speed reed switch (for
O
Pulse generator B chattering)
P0722 -open circuit- • Check the pulse generator A and B
wiring harness
Shift control solenoid valve A • Check the solenoid valve connector
• Check the shift control solenoid valve A
P0750 O
wiring harness
Shift control solenoid valve B • Check the solenoid valve connector
• Check the shift control solenoid valve B
P0755 O
wiring harness
Shift control solenoid valve C • Check the solenoid valve connector
• Check the shift control solenoid valve C
P0760 O
wiring harness
Transaxle range switch • Check the transaxle range switch
P0707
-No signal- connector and harness
O
Transaxle range switch
P0708
-Multi signal-
Pressure control solenoid - A valve • Check the pressure control solenoid
P0745
open circuit valve
O
Pressure control solenoid - B valve • Check the pressure control solenoid
P0775 valve wiring harness
shor circuit
Damper clutch control solenoid • Inspection of solenoid valve connector
P0743
• Individual inspection of damper clutch
Damper clutch control solenoid valve
P0741 -Stuck OFF- • Check the damper clutch control
O
solenoid valve wiring harness
Damper clutch • Check the PCM
P0742 -Stuck ON- • Inspection of damper clutch hydraulic
system
First gear system • Check the pulse generator A and pulse
P0731
-Malfunction- generator B connector
O
Second gear system • Check the one way clutch or rear clutch
P0732 • Check the pulse generator wiring harness
-Malfunction-
Page 43 of 116
Third gear system • Check the rear clutch or control system
-Malfunction- • Check the pulse generator A and pulse
generator B connector
• Check the front clutch slippage or control
P0733 O
system
• Check the pulse generator wiring harness
• Check the rear clutch slippage or control
system
Fourth gear system • Check the pulse generator A and pulse
-Malfunction- generator B connector
P0734 • Kickdown brake slippage O
• Check the end clutch or control system
• Check the pulse generator wiring harness
FAIL-SAFE ITEM
Note (Relation to diagnostic
DTC NO Description Fail-safe
trouble code)
Open-circuited pulse generator Locked in third (D) or When code P0717 is generated fourth
P0717
A second (2, L) gear time
Open-circuited pulse generator B Locked in third (D) or When code P0722 is generated fourth
P0722
second (2,L) gear time
Open-circuited or shorted shift Lock in third gear When code P0750 is generated fourth
P0750
control solenoid valve A time
P0755
control solenoid valve B time
P0760
control solenoid valve C time
P0745 Open-circuited shorted pressure Lock in third (D) or second When codes P0745 or P0775 are
P0775 control solenoid valve (2,L) generated fourth time
P0731 Gear shifting does not match the Lock in third (D) or second When either codes P0731, P0732,
P0732 engine speed (2,L) P0733 or P0734 are generated fourth
P0733 time
P0734
INSPECTION CHART FOR TROUBLE SYMPTOMS

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Inspection procedure Reference
Trouble symptom
No. page
Communication with scan tool is not possible 1 TR-18
Driving impossible Starting impossible (will not crank) 2 TR-19
Does not move forward 3 TR-20
Does not back-up 4 TR-21
Does not move (forward or reverse) 5 TR-22
Malfunction when Engine stalling during shifting 6 TR-23
starting
Shocks when shifting from N to D and long
7 TR-24
lag time
Shocks when shifting from N to R and long lag
8 TR-25
time
Shocks when shifting from N to D, N to R
9 TR-26
and long lag
Malfunction when
Shocks and flare shifts 10 TR-27
shifting
Early, late shift points All points 11 TR-28
Some points 12 TR-29
Does not shift Does not shift 13 TR-30
Malfunction while Poor acceleration 14 TR-31
driving Vibration 15 TR-32
Overdrive switch system 16 TR-33
INSPECTION PROCEDURE 1
Communication with scan tool is not possible Possible cause
If communiction with the scan tool is not possible, the cause may be • Malfunction of diagnosis line
a defective diagnosis line or PCM is not functioning • Malfunction of PCM power
• Malfunction of PCM ground circuit
• Malfunction of PCM
Page 45 of 116
Starting Impossible (will not crank) Possible cause
Starting is not possible when the selector lever is in P or N range. In • Malfunction of the engine system
such cases, the cause may be a defective engine system, torque • Malfunction of the oil pump
converter or oil pump. • Malfunction of the torque converter
Does not move forward Possible cause
When the engine is idling, the vehicle does not move forward even if • Abnormal line pressure
the selector lever is shifted from N to D, 2 or L range. In such • Malfunction of rear clutch
cases, the cause may be abnormal line pressure; a defective rear • Malfunction of one-way clutch
clutch or a one-way clutch. • Malfunction of valve body
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Does not move back-up Possible cause
When the engine is idling, the vehicle does not back-up even if the • Abnormal low reverse brake pressure
selector lever is shifted from N to R range. In such cases, the cause • Abnormal front clutch pressure
may be abnormal pressure in the low reverse brake or front clutch, • Malfunction of front clutch
or a defective low reverse brake or front clutch. • Malfunction of low reverse brake
• Malfunction of valve body
Page 47 of 116
Does not move (forward or reverse) Possible cause
When the engine is idling, the vehicle does not move forward or • Abnormal reducing pressure
reverse even if the selector lever is shifted from N to D, 2, L or R • Malfunction of power train
range. In such cases, the cause may be abnormal reducing pressure, • Malfunctin of oil pump
or a defective oil pump or power train. • Malfunction of valve body
Page 48 of 116
Engine stalling during shifting Possible cause
When the engine is idling, the engine stalls when the selector lever is • Malfunction of engine system
shifted from N to D, 2, L or R range. In such cases, the cause may • Malfunction of torque converter clutch
be a defective engine system or damper clutch control solenoid solenoid
valve. • Malfunction of valve body
• Malfunction of torque converter
Page 49 of 116
Shocks when shifting from N to D and long lag time Possible cause
When the engine is idling, abnormal shocks or a lag time of 2 • Malfunction of rear clutch
seconds or more occur when the selector lever is shifted from N to • Malfunction of valve body
D range. In such case, the cause may be a defective rear clutch or • Malfunction of closed throttle position
valve body. switch
Page 50 of 116
Shocks when shifting from N to R and long lag time Possible cause
When the engine is idling, abnormal shocks or a lag time of 2 • Abnormal front clutch pressure
seconds or more occurs when the selector lever is shifted from N to • Abnormal low reverse brake pressure
R range. In such cases, the cause may be abnormal low reverse • Malfunction of front clutch
brake or front clutch pressure, or a defective low reverse brake or • Malfunction of low reverse brake
front clutch.
• Malfuntion of valve body
Page 51 of 116
Shocks when shifting from N to D,N to R and long lag time Possible cause
When the engine is idling, abnormal shocks or a lag time of 2 • Abnormal reducing pressure
seconds or more occur when the selector lever is shifted from N to • Malfunction of oil pump
D range and from N to R range. In such cases, the cause may be • Malfunction of valve body
abnormal reducing pressure or a defective oil pump.
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Shocks and flare shifts Probable cause
Shocks occur when driving due to upshifting or downshifting. In • Malfunction of kickdown servo switch
addition,the engine speed during shifting increases abnormally in • Abnormal reducing pressure
comparison to normal shifting. In such cases, the cause is probably • Malfunction of valve body
abnormal reducing pressure or a defective kickdown servo switch. • Malfunction of closed throttle position
switch
• Malfunction of pressure control solenoid
valve
• Malfunction of clutches and brakes
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All points (Early, late shifting points) Possible cause
All shift points occurs early, late while driving. In such cases, the • Malfunction of pulse generator B (PG-B)
cause may be a defective pulse generator B (PG-B) or shift control • Malfunction of shift control solenoid valve
solenoid valve A or B (SCSV-A, B). A or B (SCSV-A, B)
• Abnormal reducing pressure or
kickdown servo brake application
pressure
• Malfunction of clutches and brake
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Some points (Early, late shifting points) Possible cause
Some shift points occurs early, late while driving. In such cases, the • Malfunction of valve body
cause may be a defective valve body, or it is phenomenon related to
control and is not an abnormality.
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Does not shift Possible cause
Shifting does not occur while driving, and no fail-safe codes are • Malfunction of overdrive switch
output. In such cases, the cause may be a defective overdrive switch • Malfunction of parking position switch
or parking switch. • Malfunction of power supply circuit
Poor acceleration Possible cause
While driving, acceleration is poor even if downshifting is • Malfunction of clutch and brakes
performed. In such cases, the cause may be a defective clutch, • Malfunction of engine system
brake or a defective engine system.
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Vibration Possible cause
Vibration occurs when driving at constant speed or when • Abnormal torque converter clutch
accelerating in top range. In such case, the cause may be abnormal pressure
torque converter clutch pressure or a defective torque converter. • Malfunction of engine system
• Malfunction of torque converter
• Malfunction of valve body
Overdrive switch system Possible cause
In cases such as the above, the cause may be a defective overdrive • Malfunction of overdrive switch
switch circuit or defective ignition switch circuit. • Malfunction of connector
• Malfunction of ignition switch
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OBTAINING DIAGNOSTIC TROUBLE CODES

[USING HI-SCAN PRO]
1. Turn the ignition switch OFF.
2. Connect the Hi-Scan Pro to the data link connector.
3. Turn the ignition switch ON.
4. Use the Hi-Scan Pro to check the diagnostic trouble code.
5. Repair the faulty part from the diagnosis chart.
6. Erase the diagnostic trouble code.
7. Disconnect the Hi-Scan Pro.
MALFUNCTION INDICATOR LIGHT (MIL)
An on-board diagnostic light comes on to notify the driver that there is problems in the vehicle. However, when an
irregular state returns to normal, the malfunction indicator light will go out automatically after 3 driving cycles that
have no same fault. Immediately after the ignition switch is turned on, the malfunction indicator light operates
normally. (See FL-section)
THE FOLLOWING ITEMS WILL BE INDICATED BY THE MIL
• Fluid temperature sensor
• Pulse generator A (PG-A)
• Pulse generator B (PG-B)
• Shift control solenoid valve A (SCSV-A)
• Shift control solenoid valve B (SCSV-B)
• Shift control solenoid valve C (SCSV-C)
• Pressure control solenoid valve (PCSV-A)
• Pressure control solenoid valve B (PCSV-B)
• Damper clutch solenoid valve (DCCSV)
• Shift stage synchronize
• Transaxle range switch
SERVICE DATA (WHEN A HI-SCAN PRO IS USED)
Checking procedures Checking items
Diagnosis items
Check conditions Normal value (Remedy)
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Throttle position sensor Accelerator pedal fully 2 ~ 18 % • TPS or circuit harness if
(TPS) released no change occurs
Press accelerator pedal Varies with accelerator • TPS or accelerator
slowly opening pedal cable if gradual
change is not noted
Accelerator pedal pressed 80 ~ 100%
to floor
Fluid temperature sensor Cold engine (before Equivalent to outside air • Fluid temperature
starting) temperature sensor or circuit harness
While warming up engine Gradual increase
After warming up engine 70 ~ 110°C
Kickdown servo switch L range : Idling ON • Kickdown servo
misadjusted
D range : First or third gear ON
• Kickdown servo switch
D range : Second or fourth OFF or circuit harness
gear • Kickdown servo
Engine speed P range : Idling 600 ~ 800rpm • Ignition system
Accelerator pedal : Fully • Ignition signal pick-up
closed circuit harness
P range : Idling
Accelerator pedal :
depressed
Air conditioning relay P range : Idle, air ON • Air conditioning power
signals conditioning ON relay circuit harness
P range : Idle, air
OFF
conditioning OFF
Shift position 1st speed : 10km/h First • PCM
2nd speed : 30km/h Second • Transaxle range switch
system
3rd speed : 50km/h Third
• TPS system
4th speed : 80km/h Fourth
Pulse generator A D range (OD OFF) : 1,500 ~ 2,000rpm • Pulse generator A or
driving at 50 km/h (31 circuit harness
mph) in third gear • Pulse generator A
D range (OD ON) : driving 1,700 ~ 2,000rpm shielded wire
at 80 km/h (50 mph) in • Incoming noise from
fourth gear outside
Pulse generator B D range (OD OFF) : 1,500 ~ 2,000rpm • Pulse generator B or
driving at 50 km/h (31 circuit harness
mph) in third gear • Pulse generator B
D range (OD ON) : driving 1,500 ~ 2,000rpm shielded wire
at 80 km/h (50 mph) in • Incoming noise from
fourth gear outside
Overdrive switch • Ignition switch : ON OD-ON • Overdrive switch or
• Engine : stopped circuit harness
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• Overdrive switch is
turned ON
• Ignition switch : ON OD-OFF
• Engine : stopped
• Overdrive switch is
turned OFF
Transaxle range switch Shift selector lever to P P • Transaxle range switch
range misadjusted
Shift selector lever to R R • Transaxle range switch
range or circuit harness
• Manual control cable
Shift selector lever to N N
• If selector lever is
range
inoperative, check shift
Shift selector lever to D D lock mechanism
range
Shift selector lever to 2 2
range
Shift selector lever to L L
range
Vehicle speed sensor Keep vehicle stopped 0km/h • Vehicle speed sensor if
high speed signal is
Driving at 40 km/h (25 40km/h (25 mph) delivered while vehicle
mph) in 2 range is stopping
• In other cases, vehicle
Driving at 50 km/h (31 50km/h (31 mph)
speed sensor or circuit
mph) in D range, OD OFF
harness
PCSV-A duty D range : Idling 75 ~ 90% • When accelerator pedal
is slightly pressed while
idling in D range, duty
D range : first gear 100% should become 100%
• PCM
• TPS system
PCSV-B duty D range : Idling 0% • PCM
D range : first gear 0% • TPS system
Torque converter slip D range : third gear, 0~50rpm • Torque converter

amount 70km/h, OD OFF • Ignition signal wire or
pulse generator A
system
• Inappropriate transaxle
fluid pressure
• Torque converter
control solenoid valve
DCCSV duty D range : third gear, 40 ~ 85% • PCM
70km/h, OD OFF • TPS system
Page 60 of 116
• Pulse generator A
system
• Torque converter
control solenoid valve
ELEMENTS IN USE IN EACH GEAR

Select or Overdrive Clutch Brake
Shifting Engine Parking
lever control
gear start Mechanism C1 C2 C3 OWC B1 B2
position switch
P - Neutral Possible O
R - Reverse O O
N - Neutral Possible
D ON First O O
Second O O
Third O O O
Fourth O O
D OFF First O O
Second O O
Third O O O
2 - First O O
Second O O
L - First O O
C1 : Front clutch
C2 : Rear clutch
C3 : End clutch
OWC : One way clutch
B1 : Kickdown brake
B2 : Low&reverse brake
INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS
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OIL PRESSURE TESTS

1. Completely warm up the transaxle.
2. Raise the front of the vehicle so that the front wheels can be rotated.
3. Connect an engine tachometer and place it in a position where it's easy to see.
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4. Attach the special oil-pressure gauge (09452-21500) and the adapter (09452-21002) to each oil-pressure outlet
port.
When the reverse pressure is to be tested, the 3,000 kpa (400 psi) type of gauge should be used.
5. Measure the oil pressure under various conditions. Check to be sure that the measured results are within the standard
value range shown in the "Standard oil pressure table" below. If the oil pressure is not within the specified range,
check and repair as described in the section "Preliminary Steps if Oil Pressure Is Not Normal" on the next page.
STANDARD OIL PRESSURE TABLE

Page 68 of 116
- must be 19.6 kPa (2.8 psi) or less.

PRELIMINARY STEPS IF OIL PRESSURE IS NOT NORMAL
Trouble symptom Probable cause Remedy
Line pressures are all low (or • Obstructed oil filter • Visually inspect the oil filter; replace
high). • Improper adjustment of oil the oil filter if it is restricted.
Line pressure refers to oil pressure (line pressure) regulator • Measure line pressure 2 (kickdown
pressures 2, 3, 4, 5, 6, 7 and 8 valve brake pressure); if the pressure is
in the "Standard oil pressure • Sticking of regulator valve notthe standard value, readjust the line
table" on the previous page. • Looseness of valve body pressure, or if necessary, replace
tightening part thevalve body assembly.
• Improper oil pump discharge • Check the operation of the regulator
pressure valve; repair if necessary, or replacethe
valve body assembly.
• Tighten the valve body tightening bolt
and installation bolt.
• Check the side clearance of the oil
pump gear; replace the oil pump
assembly if necessary.
Improper reducing pressure • Improper line pressure • Check the 2 kickdown brake pressure
• Clogging of the filter (L-shaped (line pressure); if the line pressure is
type) of the reducing-pressure not the standard value, check as
circuit described in item 1 above.
• Improper adjustment of the • Disassemble the valve body assembly
reducing pressure and check the filter; replace the filter if
• Improper adjustment of the it is restricted.
reducing pressure • Measure the 1 reducing pressure; if it is
• Sticking of the reducing valve not the standard value, readjust, or
• Looseness of valve body replace the valve body assembly.
tightening part
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• Looseness of valve body
tightening part • Check the operation of the reducing
valve; if necessary, repair it, or replace
the valve body assembly.
• Tighten the valve body tightening bolt
and installation bolt.
Improper kickdown brake • Malfunction of the D ring or seal • Disassemble the kickdown servo and
pressure ring or the sleeve or kickdown check whether the seal ring or D-ring is
servo piston. damaged. If it is cut or has scratches,
• Looseness of valve body replace the seal ring or D-ring.
tightening part. • Tighten the valve body tightening bolt
• Functional malfunction of the valve and installation bolt.
body assembly. • Replace the valve body assembly.
Improper front clutch pressure • Malfunction of the D-ring of the • Disassemble the kickdown servo and
sleeve or kickdown servo piston. check whether the seal ring is
• Looseness of valve body damaged.If it is cut or has scratches,
tightening part replace the seal ring or D-ring.
• Malfunction of the valve body • Tighten the valve body tightening bolt
assembly. and installation bolt.
• Wear of the front clutch piston or • Replace the valve body assembly.
retainer, or malfunction of the D- • Disassemble the transaxle itself and
ring. (Refer to the figure on the check whether or not there is wear of
next page.) the front clutch piston and retainer
• Oil pump gasket or seal ring (2) inner circumference, or damage of the
damaged. D-ring. If there is any wear or damage,
replace the piston, retainer, D-ring and
or seal ring.
Improper end clutch pressure • Malfunction of a D-ring, seal ring • Disassemble the end clutch and check
of the end clutch or O-ring of the the seal ring, D-ring of the piston, seal
pipe (Refer to the figure on the ring of the retainer, etc.; replace if there
next page.) are cuts, scars, scratcher or damage.
• Looseness of valve body • Tighten the valve body tightening bolt
tightening part. and installation bolt.
• Malfunction of the valve body • Replace the valve body assembly.
assembly
Improper low-reverse brake • O-ring between valve body and • Remove the valve body assembly and
pressure transaxle damaged or missing check to be sure that the O-ring at the
• Looseness of valve body upper surface of the upper valve body
tightening part is not missing or damaged; install or
• Malfunction of the valve body replace the O-ring if necessary.
assembly • Tighten the valve body tightening bolt
• Malfunction of the O-ring of the and installation bolt.
low-reverse brake piston or the • Replace the valve body assembly.
O-ring of the retainer (Refer to the • Disassemble the transaxle itself and
figure on the next page.) check the O-ring for damage; replace
if there are cuts, scars, scratches or
damage.
Improper torque converter
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Improper torque converter • Sticking of the damper clutch • Check the operation of the damper
pressure control solenoid valve (DCCSV) clutch system and the DCCSV.
• Clogging or leaking of the oil • Repair or replace, as necessary, the
cooler and/or lines. cooler and/or lines.
• Damaged seal ring of the input • Disassemble the transaxle itself and
shaft. check for damage of the seal ring;
• Malfunction of the torque replace the seal ring if there is damage.
converter. • Replace the torque converter.
Improper rear clutch pressure • Malfunction of the D-ring or seal • Tighten the value body tightening bolt
ring of the rear clutch. and installation bolt.
• Looseness of valve body • Replace the valve body assembly.
tightening part.
• Functional malfunction of the valve
body assembly.
Improper damper clutch Same as the probable cause of Same as the remedy of damper clutch
release pressure. damper clutch release pressure release pressure.
SEAL INSTALLATION
Page 71 of 116
CONVERTER STALL TEST

A stall test determines the maximum engine speed obtained at full throttle in "D" and "R" range. This test checks the
torque converter stator overrunning clutch operation, and the holding ability of the transaxle clutches and the low-
reverse brake.
During this test, make sure that nobody stands in front of or behind the vehicle.
1. Check transaxle fluid level. Fluid should be at normal operating temperature [80~90°C (176~194°F)]. Engine
coolant should also be at normal operating temperature [80~90°C (176~194°F)].
Page 72 of 116
2. Apply chocks to both rear wheels.
3. Attach an engine tachometer.
4. Apply the parking and service brakes fully.
5. Start the engine.
6. With the selector lever in the "D" position, depress the accelerator pedal fully to read maximum engine rpm. Do
not hold the throttle wide open any longer than is necessary to obtain maximum engine rpm reading, and never
longer than 5 seconds at a time. If more than one stall test is required, operate the engine at approximately 1,000
rpm in neutral for 2 minutes to cool the transaxle fluid between tests.
Stall speed: 2,200~2,800rpm
7. Place the selector lever in the "R" position and perform the stall test by the same procedure as previously
described.
STALL SPEED ABOVE SPECIFICATION IN "D"
If stall speed is higher than specification, the rear clutch or overrunning clutch of the transaxle is slipping. In this case,
perform a hydraulic test to locate the cause of slippage.
STALL SPEED ABOVE SPECIFICATION IN "R"
If the stall speed is higher than specification, the front clutch of the transaxle or low-reverse brake is slipping. In this
case, perform a hydraulic test to locate the cause of slippage.
STALL SPEED BELOW SPECIFICATION IN "D" AND "R"
If the stall speed is lower than specification, insufficient engine output or a faulty torque converter is suspected.
Check for engine misfiring, improper ignition timing, or valve clearance etc. If these are good, the torque converter is
faulty.
TRANSAXLE FLUID LEVEL INSPECTION
1. Drive the vehicle until the fluid reaches normal operating temperature [80~90°C (176~194°F)].
2. Place the vehicle on a level surface.
3. Move the selector lever through all gear positions. This will fill the torque converter and hydraulic system with
fluid, then place lever in "N" (Neutral) position.
4. Before removing the dipstick, wipe all contaminants from around the dipstick. Then take out the dipstick and
check the condition of the fluid. The transaxle should be overhauled under the following conditions.
A. If there is a "burning" door.
B. If the fluid color has become noticeably black.
C. If there is a noticeably excessive amount of metal particles in the fluid.
5. Check to see if the fluid level is in the "HOT" range on dipstick. If fluid level is low, add automatic transaxle fluid
until the level reaches the "HOT" range.
Transaxle fluid: DIAMOND ATF SP-III, SK ATF SP-III
Low fluid level can cause a variety of abnormal conditions because it allows the pump to take in air along with
fluid. Air trapped in the hydraulic system forms bubbles which are compressable. Therefore, pressures will be
erratic, causing delayed shifting, sliping clutches and brakes, etc. Improper filling can also raise fluid level too high.
When the transaxle has too much fluid, gears churn up foam and cause the same conditions which occur with low
fluid level, resulting in accelerated deterioration of automatic transaxle fluid. In either case, air bubbles can cause
overheating, and fluid oxidation, which can interfere with normal valve, clutch, and servo operation. Foaming can
also result in fluid escaping from the transaxle vent where it may be mistaken for a leak.
Page 73 of 116
6. Be sure to examine the fluid on the dipstick closely.
When new, automatic transmission fluid should be red. The red dye is added so distinguish it from engine
oil or antifreeze. As the vehicle is driven the transmission fluid will begin to look darker. The color may
eventually appear light brown.
Also, the dye, which is not an indicator of fluid quality, is not permanent.
Therefore, further investigation of the automatic transaxle is required if,
• the fluid is dark brown or black.
• the fluid smells burnt.
• metal particles can be seen or felt on the dipstick.
SELECTOR LEVER OPERATION CHECK

1. Shift the selector lever to each range and check to see that the lever moves smoothly and is controlled. Check to
see that the position indicator is correct.
2. Check to be sure that the selector lever can be shifted to each position.
3. Start the engine and check to see if the vehicle moves forward when the selector lever is shifted from "N" to "D"
and moves backward when shifted to "R".
4. When the shift lever malfunctions, adjust the control cable and the selector lever sleeve. Check for worn shift
lever assembly sliding parts.
TRANSAXLE RANGE SWITCH ADJUSTMENT
1. Place selector lever in "N" (Neutral) position.
2. Loosen the manual control lever lock nut to seperate the cable and lever.
3. Place the manual control lever in the "N" (Neutral) position.

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4. Turn the transaxle range switch body until the 12 mm (0.47 in.) wide end of the manual control lever aligns with
the switch body flange [12 mm (0.472 in.) wide portion].
5. Tighten the attaching bolts (2 pcs.) to the specified torque.
Transaxle Range Switch Attaching Bolt:

10~12 Nm (100~120 kg·cm, 7~9 lb·ft)
When setting up the switch body, be careful that the O-ring does not drop from the switch body. Tighten
the attaching bolts carefully.
6. Make sure that the selector lever is in the "N" (Neutral) position.
7. Adjust the flange nut so that there is no slack in the control cable and make sure that the selector lever operates
smoothly.
8. Run the vehicle and confirm that the transaxle is set in each range when the selector lever is shifted to each
position.
KICKDOWN SERVO ADJUSTMENT

1. Completely remove all dirt and other contaminating materials adhered around the kickdown adjust screw.
2. Loosen the lock nut.
3. Loosen and tighten the adjust screw two times by torque of 5 Nm (3.6 lb·ft)
4. Tighten adjust screw by torque of 5 Nm and then, loosen the adjust screw 3 to 3-1/3 turns.
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5. Tighten the lock nut to the specified torque.
Lock nut: 15~22 Nm (150~220 kg·cm, 11~16 lb·ft)
Before assembling, apply sealant (DC780) to the center portion of the adjust screw.
LINE PRESSURE ADJUSTMENT

1. Drain out the automatic transaxle fluid.
2. Remove the oil pan.
3. Remove the oil filter.
4. Remove the oil-temperature sensor.

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5. Press the tab of the solenoid valve harness grommet and push in.
6. Remove the valve body assembly. The manual valve can come out, so be careful not to drop it.
7. Turn the adjustment screw of the regulator valve and adjust so that the line pressure (kickdown brake pressure)
reaches the standard value. When the adjustment screw is turned clockwise, the line pressure becomes lower;
when it is turned counter-clockwise, it becomes higher.
Standard value:
860~900 kPa (122~129 psi, 8.77~9.18 kg/cm²)
Oil pressure change for each turn of adjustment screw:
38 kPa (5.4 psi, 0.39 kg/cm²)
8. Check to be sure that the O-ring is installed on the upper surface of the valve body in it's proper place.
9. Replace the O-ring of the solenoid valve connector with a new one.
10. Install the valve body assembly to the case and then insert the solenoid valve connector into the case. Be sure,
at this time, that the notched part of the connector faces as shown in the figure. Also be careful that the lead
wiring isn't caught.
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11. Tighten the valve body assembly mounting bolts to 10-12 Nm (100-120 kg·cm, 7-9 lb·ft).
12. Install the oil filter.
13. Install a new oil pan gasket with the oil pan.
14. Add the specified amount of automatic transaxle fluid.
15. Perform the oil pressure test. Readjust if necessary.
REDUCING PRESSURE ADJUSTMENT
If the Scan Tool is not abailable
1. Remove parts up to the oil filter in the same way as for adjustment of the line pressure. The valve body need not
be removed.
2. Turn the adjustment screw of the lower valve body and adjust so that the reducing pressure is the standard value.
When the adjustment screw is turned clockwise, the reducing pressure becomes lower; when it is turned counter
clockwise, it becomes higher.
When adjusting the reducing pressure, aim for the center value (425 kPa, 60 psi) of the standard value
allowance.
Standard value:
420 kPa (60 psi, 4.2±0.2 kg·cm²)
Oil pressure change for each turn of the adjustment screw:
22 kPa (4.3 psi, 0.22 kg·cm²)
3. Install the oil filter and oil pan in the same way as for adjustment of the line pressure.
4. Peform the oil pressure test. Readjust if necessary.
If the Scan Tool is used
1. Adjust the pressure control solenoid so that the kickdown brake pressure is the standard value when activated to
50% duty by the Scan Tool.
Standard value:
320±30 kPa (39±1 psi, 3.2±0.3 kg·cm²)
Oil pressure change for each turn of the adjustment screw:
30 kPa (3 psi, 0.3 kg·cm²)
2. Check to be sure that the reducing pressure (after the adjustment is completed) is within the range of 370~490
kPa (53~70 psi, 3.8~5.0 kg·cm²).
This adjustment should be made with an oil temperature of 80-90°C (176-194°F). If the adjustment is
made at a temperature that is too high, the line pressure will drop during idling, with the result that it might
not be possible to make the correct adjustment.
Page 78 of 116
THROTTLE POSITION SENSOR INSPECTION
Refer to GROUP FUEL SYSTEM.
DRIVE SHAFT OIL SEALS REPLACEMENT
1. Disconnect the drive shaft from the transaxle. (Refer to DRIVE SHAFT&FRONT AXLE)
2. Using a flat-tip (-) screwdriver, remove the oil seal.
3. Using the special tool (09431-21200), tap the drive shaft oil seal into the transaxle.
4. Apply a coating of the transaxle fluid to the lip of the oil seal.
PCM REPLACEMENT
PCM (Power Control Module) is located at the dash panel of the upper side of brake pedal in the driver side.
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Components and
Components Location
SHIFT LEVER ASSEMBLY
Page 79 of 116
Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Repair
procedures
INSPECTION
• Check the detent place for wear.
• Check the bushing for wear or damage.
• Check the spring for damage or deterioration.
• Check the pin at the end of the rod assembly for wear.
Page 80 of 116
REASSEMBLY
1. Apply a coating of grease to the sliding part of the bushing.
Specified grease:
Chassis grease SAE J310, NLGI No.2
2. Apply the specified grease at the places shown in the figure.
Specified grease:
Multipurpose grease SAE J310, NLGI No.2
Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Shift Control >
Components and Components Location
COMPONENTS
Page 81 of 116
Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Shift Control >
Repair procedures
REMOVAL
Page 82 of 116
1. Remove the rear console.
2. Remove the front console.
3. Remove the knob installation screws.

4. Disconnect the overdrive switch connector, remove the 3 connector pins from connector with small driver, and
then remove selector knob assembly.
5. Disconnect the position indicator light connector.
6. Remove the shift lever indicator assembly.

Page 83 of 116
7. Remove the cotter pin.
8. Remove the clip from the shift lever side.
9. Remove the bolt-washer assembly located on dash panel.
10. Remove the shift lever assembly.

11. Remove the transaxle control cable assembly.
INSTALLATION
Page 84 of 116
1. Apply a coating of the specified grease to the interior of the bushing.
Specified grease:
Chassis grease SAE J310, NLGI No.0
2. Move the shift lever and the transaxle range switch to the N position, and install the control cable.
3. When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts the control
cable.
4. Install the bolt-washer assembly and nut.

Page 85 of 116
5. Install the clip pin and self lock pin.
6. Install the cotter pin.
7. Connect the position indicator light connector, the O/D switch connector, the parking position switch connector,
normal/economy select switch connector and the shift lock solenoid connector.
8. Install the shift lever indicator assembly.

Page 86 of 116
9. Apply the specified grease at the place shown in the figure.
Specified grease:
10. Install the shift lever assembly.

11. Place the shift lever in the N position, and then turn the cam adjusting so that the clearance between the cam
adjusting and the lever assembly end in within the standard value.
Standard value (A) 15.2-15.9 mm (0.598-0.625 in.)
Be sure to face B of the adjusting cam to the push button (driver's side).
12. Insert the O/D switch wiring to the shift lever cover, and then assemble the pin into the O/D switch connector.
13. Install the front console.
Page 87 of 116
14. Install the rear console.
ADJUSTMENT OF CONTROL CABLE

1. Eliminate slack from the control cable with the adjusting flange nut and check that the select lever operates
smoothly.
2. Driving the car, check that the transaxle is set in the proper range when the select lever is shifted to each position.
INSPECTION
1. Check the control cable for function and damage.
2. Check the bushing for wear or damage.
3. Check the spring for damage or deterioration.
4. Check the overdrive switch for continuity.
Automatic Transaxle System > Troubleshooting > P0707

DTC TROUBLESHOOTING PROCEDURE
INSPECTION PROCEDURES FOR DIAGNOSTIC TROUBLE CODES
DTC NO DIAGNOSTIC ITEM
P0707 TRANSAXLE RANGE SWITCH (TR Open, GND short
P0708 SWITCH) Short
DESCRIPTION
The PCM monitors this voltage, which corresponds to the position of the transaxle gear shift lever to determine
desired gear and electronic pressure control pressure. The transaxle range switch is located on the top of the
transaxle, and also contains the neutral/start circuit.
TROUBLESHOOTING FLOW
Page 88 of 116
Detection condition Possible cause Check item
1. No signal is continuous for > 30 • Malfunction of TR switch • Harness & connector
seconds • Malfunction of connector • Transaxle range switch
2. Above 2 signals are continuous for > • Malfunction of PCM
30 seconds
• Engine speed ≥ 600rpm
SYMPTOM
• Starting impossible
• Does not move
CIRCUIT DIAGRAM
INSPECTION PROCEDURES
Page 89 of 116

FLUID (OIL) TEMPERATURE
P0711 - Rationality check -
SENSOR SYSTEM
DESCRIPTION
• The automatic TRANSAXLE fluid(ATF) temperature sensor is installed in the Valve Body. This sensor uses a
thermistor whose resistance changes according to the temperature changes. The TCM supplies a 5V reference
voltage to the sensor, and the output voltage of the sensor changes when the ATF temperature varies. The
automatic TRANSAXLE fluid(ATF) temperature provides very important data for the TCM's control of the
Torque Converter Clutch, and is also used for many other purposes.
TROUBLESHOOTING GUIDE
Page 90 of 116
Detection condition
Threshold Possible cause Check item
Malfunction Criteria
Value
• Stuck signal • Fluid temperature • Fluid temperature
• Tsc – Tsi sensor sensor
Tsc : current temperature • TCM • Harness & connector
<5 °C
Tsi : InitialTemperature
(Initialization is first satisfied for
monitoring condition)
• Variation of oil temperature
• | Tjc – Tji |
>10°C
Tjc : current temperature
Tji : old temp. before 10 sec
• Stuck of High temperature
>15°C
• Oil temperature - Coolant temp
• Accumulated time interval to satisfy
Enable condition.
• T_Tar : Time interval to reach target >T_tar
temperature after cranking. This map
depends on oil temperature at cranking.
Page 91 of 116

Page 92 of 116
P0712 Short to ground side
SENSOR SYSTEM
P0713 Open
SENSOR SYSTEM
• 10 minutes after engine speed>1000 Malfunction • Fluid temperature sensor
rpm • Fluid temperature sensor • Harness & connector
• 10 minutes after pulse generator • PCM
B>1000 rpm
• Low temperature side output
voltage>4.3 V
SYMPTOM
• Shift shock
• Power shift pattern will not be available
CIRCUIT DIAGRAM
Page 93 of 116

P0712 Short to ground side
SENSOR SYSTEM
P0713 Open
SENSOR SYSTEM
• 10 minutes after engine speed>1000 Malfunction • Fluid temperature sensor
rpm • Fluid temperature sensor • Harness & connector
• 10 minutes after pulse generator • PCM
B>1000 rpm
• Low temperature side output
voltage>4.3 V
SYMPTOM
• Shift shock
• Power shift pattern will not be available
CIRCUIT DIAGRAM
Page 94 of 116

- Open, short
P0717 PULSE GENERATOR A
circuit -
Page 95 of 116
DESCRIPTION
• Detects non-operating area of damper clutch.
• Detects turbine rpm for control of fluid pressure during a shift.
• Vehicle speed sensor speed>30km/h • Malfunction of PG-A • Harness & connector
• Transaxle range : D, 2 or L • Malfunction of connector
• Engine speed>3,000rpm • Malfunction of PCM
• Shift position : 2nd, 3rd or 4th gear • Malfunction of end clutch
retainer
SYMPTOM
• Shift shock during 2nd and 4th gear
shifting.
• When code P0717 is generated,
automatic transaxle hold in 3rd gear ("D"
range) or 2nd gear ("2", "L" range).
• Codes P0731, P0732, P0733 and
P0734 may also be set.
Page 96 of 116

DTC
DIAGNOSTIC ITEM
NO
P0722 PULSE GENERATOR B - Open, short -
DESCRIPTION
Page 97 of 116
• Detects number of revolutions of the transfer driven gear to monitor vehicle speed.
• Vehicle speed sensor speed>30 km/h • Malfunction of PG-B • Open in PG-B circuit
• Engine speed>3,000 rpm • Malfunction of connector • Malfunction of PG-B
• Shift position : 2nd, 3rd or 4th gear • Malfunction of PCM • Noise in signal (Poor or
• Malfunction of transfer driven defective shielding)
SYMPTOM
gear • Chattering of vehicle speed
• Shift shock during 2nd and 4th gear
sensor
shifting
• When fail-safe code P0722 is generated,
automatic transaxle will hold in 3rdgear
(D) or 2nd gear (2,L)
• Codes P0731, P0732, P0733 and
P0734 may also be set
CIRCUIT DIAGRAM
Page 98 of 116

FIRST GEAR INCORRECT - MALFUNCTION
P0731
RATIO -
DESCRIPTION
• If the value resulting from driving the PG-A output (input shaft rotation speed) by the 1st gear ratio does not
match the PG-B output (output shaft rotation speed) after 1st gear is engaged, DTC P0731 is output.
Page 99 of 116
• Engine speed>400 rpm Malfunction • Malfunction of pulse
• Transfer shaft speed>900 rpm • PG-A or PG-B generator circuit
• Fluid temperature>60°C • Transfer driven gear • Rear clutch slippage
• PCM senses a signal that does not fall • Rear clutch • One-way clutch slippage
into the preprogrammed parameters • One-way clutch
SYMPTOM
• Automatic transaxle will hold 3rd gear
• Code P0717 or P0722 may also be set
(pulse generator codes)
Page 100 of 116

-
P0732 SECOND GEAR SYSTEM MALFUNCTION
-
DESCRIPTION
• If the value resulting from driving the PG-A output (input shaft rotation speed) by the 2nd gear ratio does not
match the PG-B output (output shaft rotation speed) after 2nd gear is engaged, DTC P0732 is output.
• If the value resulting from driving the PG- Malfunction • Malfunction of pulse
A output (input shaft rotation speed) by • PG-A or PG-B generator circuit
the 2nd gear ratio does not match the • Transfer driven gear • Rear clutch slippage
PG-B output (output shaft rotation • Rear clutch • Kickdown brake slippage
speed) after 2nd gear is engaged, DTC • Kickdown brake
P0732 is output
SYMPTOM
• Automatic transaxle will hold in 3rd gear
Page 101 of 116
Page 102 of 116

-
P0733 THIRD GEAR SYSTEM MALFUNCTION
-
DESCRIPTION
• If the value resulting from driving the PG-A output (input shaft rotation speed) by the 3rd gear ratio does not
match the PG-B output (output shaft rotation speed) after 3rd gear is engaged, DTC P0733 is output.
• Transfer shaft speed>900 rpm • PG-A or PG-B generator circuit
• Fluid temperature>60°C • Transfer driven gear • Rear clutch slippage
• PCM senses a signal that does not fall • End clutch retainer • Front clutch slippage
into the preprogrammed parameters • Front clutch
SYMPTOM
• Automatic transaxle will hold 3rd gear (D) or 2nd gear (2, L) when code P0731, P0732, P0733, P0734 is
output
• Code P0717 or P0722 may also be set (pulse generator codes)
Page 103 of 116
Page 104 of 116

-
P0734 FOURTH GEAR SYSTEM MALFUNCTION
-
DESCRIPTION
• If the value resulting from driving the PG-A output (input shaft rotation speed) by the 4th gear ratio does not
match the PG-B output (output shaft rotation speed) after 4th gear is engaged, DTC P0734 is output.
• Transfer shaft speed >900 rpm • PG-B generator circuit
• Fluid temperture>60°C • Transfer driven gear • Kickdown brake slippage
• PCM senses a signal that does not fall • End clutch retainer
into the preprogrammed parameters. • Kickdown brake
SYMPTOM • End clutch
• Automatic transaxle will hold in 3rd gear
(D) or 2nd gear (2, L) when code
P0731, P0732, P0733, P0734 is output.
• Code P0717 or P0722 may also be set
(pulse generator codes).
Page 105 of 116
Page 106 of 116

DAMPER CLUTCH CONTROL
P0743 - Open, Short circuit -
SOLENOID VALVE
P0742 DAMPER CLUTCH SYSTEM - Stuck ON -
P0741 DAMPER CLUTCH SYSTEM - Stuck OFF -
DESCRIPTION
• Controls fluid pressure that is acting on the damper clutch control valve through Pulse Width Modulation signals
from the PCM to control the operation of the damper clutch.
• If damper clutch solenoid drive duty continues at 100% for 4 sec. or more, there is an abnormality in the damper
clutch control system at DTC P0743 is output.
• IG S/W "ON" or start release • Malfunction of connector • Open/short in DCCSV
• PCM senses an open • Malfunction of PCM circuit
• Short in DCCSV circuit • Malfunction of DCCSV
SYMPTOM
• Excessive fuel consumption
• Poor performance
Page 107 of 116

SOLENOID VALVE
DESCRIPTION
• If damper clutch solenoid drive duty continues at 100% for 4 sec. or more, there is an abnormality in the damper
clutch control system at DTC P0743 is output.
SYMPTOM
Page 108 of 116

SOLENOID VALVE
DESCRIPTION
• If damper clutch solenoid drive duty continues at 100% for 4 sec. or more, there is an abnormality in the
damper clutch control system at DTC P0743 is output.
SYMPTOM
Page 109 of 116

PRESSURE CONTROL SOLENOID
P0745 - Open -, - Short circuit -
VALVE-A
DESCRIPTION
• Controls fluid pressure that is acting on the pressure control valve-A (PCV-A) through Pulse Width
Modulation signals from the PCM to control pressure during a shift.
• IG S/W "ON" or start release • Malfunction of PCSV-A • Open/short in PCSV-A
• PCM senses an open • Malfunction of connector circuit
• Short in the PCSV-A circuit • Malfunction of PCM • Malfunction of PCSV-A
SYMPTOM
• Shock felt as transaxle is engaged
• Shift shock is felt as transaxle shifts
through gears
• Abrupt increase of engine rpm
• When code P0745 is generated for the
4th time, automatic transaxle will hold 3rd
gear (D) or 2nd gear (2,L)
CIRCUIT DIAGRAM
Page 110 of 116

P0750 SHIFT CONTROL SOLENOID - Open -, - Short circuit
VALVE A -
DESCRIPTION
Page 111 of 116
• Control fluid pressure that is acting on the shift control valve (SCV) through ON/OFF signals from the PCM to
control shifting.
• IG S/W "ON" or start release • Malfunction of PG-A • Open/short in SCSV-A
• PCM senses an open/short in the SCSV- • Malfunction of connector circuit
A • Malfunction of PCM • Malfunction of SCSV-A
SYMPTOM
when code P0750 is generated.
CIRCUIT DIAGRAM
Page 112 of 116

VALVE B -
DESCRIPTION
• Controls fluid pressure that is acting on the shift control valve (SCV) through ON/OFF signals from the PCM
to control shifting.
• If resistance value of SCSV-B is too high or low, P0755 is output (open or short circuit).
• IG S/W "ON" or start release • Malfunction of SCSV-B • Open/short in SCSV-B
B • Malfunction of PCM • Malfunction of SCSV-B
SYMPTOM
CIRCUIT DIAGRAM
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VALVE C -
DESCRIPTION
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• Controls fluid pressure that is acting on the control switch valve (CSV) through ON/OFF signals from the
PCM to control shifting
• If resistance value of SCSV-C is high, P0760 is output (open circuit).
• IG S/W "ON" or start release • Malfunction of SCSV-C • Open/short in SCSV-C
C • Malfunction of PCM • Malfunction of SCSV-C
SYMPTOM
CIRCUIT DIAGRAM
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PRESSURE CONTROL SOLENOID
P0775 - Open -, - Short circuit -
VALVE-B
DESCRIPTION
• Controls fluid pressure that is acting on the pressure control valve-B (PCV-B) through Pulse Width Modulation
signals from the PCM to control pressure during a shift.
• IG S/W "ON" or start release • Malfunction of PCSV-B • Open/short in PCSV-B
• PCM senses an open • Malfunction of connector circuit
• Short in the PCSV-B circuit • Malfunction of PCM • Malfunction of PCSV-B
SYMPTOM
• Shock felt as transaxle is engaged
• Shift shock is felt as transaxle shifts
through gears
• Abrupt increase of engine rpm
• When code P0775 is generated for the
4th time, automatic transaxle will hold 3rd
gear (D) or 2nd gear (2,L)
CIRCUIT DIAGRAM
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ACCENT(LC) > 2005 > G 1.5 SOHC > Body Electrical System
Body Electrical System > General Information > General Information

GENERAL TROUBLESHOOTING INFORMATION
BEFORE TROUBLESHOOTING
1. Check applicable fuses in the appropriate fuse/relay box.
2. Check the battery for damage, state of charge, and clean and tight connections.
• Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you
will damage the alternator diodes.
• Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely
damage the wiring.
3. Check the alternator belt tension.

HANDLING CONNECTORS
1. Make sure the connectors are clean and have no loose wire terminals.
2. Make sure multiple cavity connectors are packed with grease (except watertight connectors).
3. All connectors have push-down release type locks (A).
4. Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another
component. This clip has a pull type lock.
5. Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector
from its mount bracket (A).
6. Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
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7. Always reinstall plastic covers.
8. Before connecting connectors, make sure the terminals (A) are in place and not bent.
9. Check for loose retainer (A) and rubber seals (B).
10. The backs of some connectors are packed with grease. Add grease if necessary. If the grease is contaminated,
replace it.
11. Insert the connector all the way and make sure it is securely locked.
12. Position wires so that the open end of the cover faces down.
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HANDLING WIRES AND HARNESSES
1. Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
2. Remove clips carefully; don't damage their locks (A).
3. Slip pliers(A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the
clip.
4. After installing harness clips, make sure the harness doesn't interfere with any moving parts.
5. Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and
from exposed screws and bolts.
6. Seat grommets in their grooves properly (A). Do not leave grommets distorted (B).
TESTING AND REPAIRS

1. Do not use wires or harnesses with broken insulation.
Replace them or repair them by wrapping the break with electrical tape.
2. After installing parts, make sure that no wires are pinched under them.
3. When using electrical test equipment, follow the manufacturer's instructions and those described in this manual.
4. If possible, insert the probe of the tester from the wire side (except waterproof connector).
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5. Use a probe with a tapered tip.
FIVE-STEP TROUBLESHOOTING
1. Verify the complaint
Turn on all the components in the problem circuit to verify the customer complaint. Note the symptoms. Do not
begin disassembly or testing until you have narrowed down the problem area.
2. Analyze the schematic
Look up the schematic for the problem circuit.
Determine how the circuit is supposed to work by tracing the current paths from the power feed through the
circuit components to ground. If several circuits fail at the same time, the fuse or ground is a likely cause.
Based on the symptoms and your understanding of the circuit operation, identify one or more possible causes of
the problem.
3. Isolate the problem by testing the circuit
Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the
key to efficient troubleshooting.
Test for the most likely cause of failure first. Try to make tests at points that are easily accessible.
4. Fix the problem
Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures.
5. Make sure the circuit works
Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the
problem was a blown fuse, be sure to test all of the circuits on the fuse. Make sure no new problems turn up and
the original problem does not recur.
Body Electrical System > General Information > Special Service Tools
SPECIAL TOOLS
Tool (Number and Name) Illustration Use
09900-21300 Store transmitter code connecting the DLC
Keyless adapter (Data Link Connector) cable of Hi-scan to
the multi purpose check connector.
Body Electrical System > General Information > Troubleshooting

TROUBLESHOOTING
INSTRUMENTS AND WARNING SYSTEM
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Symptom Possible cause Remedy
Tachometer does not operate No.2 fuse (10A) blown Check for short and replace
Tachometer faulty fuse
Wiring faulty Check tachometer
Repair if necessary
Fuel gauge does not operate No.2 fuse (10A) blown Check for short and replace
Fuel gauge faulty fuse
Fuel sender faulty Check gauge
Wiring faulty Check fuel sender
Repair if necessary
Low fuel warning lamp does not light No.2 fuse (10A) blown Check for short and replace
Bulb burned out fuse
Fuel level sensor faulty Replace bulb
Wiring or ground faulty Check sensor
Repair if necessary
Water temperature gauge does not No.2 fuse (10A) blown Check for short and replace
operate Water temperature gauge faulty fuse
Water temperature sender faulty Check gauge
Wiring or ground faulty Check sender
Repair if necessary
Oil pressure warning lamp does not light No.2 fuse (10A) blown Check for short and replace
Oil pressure switch faulty Replace bulb
Wiring or ground faulty Check switch
Repair if necessary
Low brake fluid warning lamp does not No.2 fuse (10A) blown Check for short and replace
light Bulb burned out fuse
Brake fluid level warning switch Replace bulb
faulty Check switch
Parking brake switch faulty Check switch
Wiring or ground faulty Repair if necessary
Open door warning lamp does not light Room lamp fuse (10A) blown Check for short and replace
Battery fusible link (50A) blown fuse
Bulb burned out Replace the fusible link
Door switch faulty Replace bulb
Repair if necessary
Seat belt warning lamp does not light No.2 fuse (10A) blown Check for short and replace
Buckle switch faulty Replace bulb
Wiring or gound faulty Check switch
Repair if necessary
LIGHTING SYSTEM
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One lamp does not light Bulb burned out Replace bulb
(all exterior) Socket, wiring or ground faulty Repair if necessary
Head lamps do not light Bulb burned out Replace bulb
No.10 fuse (10A) blown Check for short and replace
Fusible link (50A) blown fuse
Head lamp relay faulty Replace the fusible link
Lighting switch faulty Check relay
Repair if necessary
Tail lamps and license plate lamps do Replace fuse and check for
Tail lamp fuse (10A) blown
not light short
Battery fusible link (50A) blown
Replace the fusible link
Tail lamp relay faulty
Check relay
Lighting switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Stop lamps do not light No.8 fuse (10A) blown Replace fuse and check for
Stop lamp switch faulty short
Wiring or ground faulty Adjust or replace switch
Repair if necessary
Stop lamps stay on Stop lamp switch faulty Adjust or replace switch
Instrument lamps do not light Rheostat faulty Check rheostat
(Tail lamps light) Wiring or ground faulty Repair if necessary
Turn signal lamp does not flash on one Bulb burned out Replace bulb
side Turn signal switch faulty Check switch
Wiring or ground faulty Repair if necessary
Turn signal lamps do not operate No.1 fuse (10A) blown Replace fuse and check for
Flasher unit faulty short
Turn signal switch faulty Check flasher unit
Repair if necessary
Hazard warning lamps do not operate No.7 fuse (10A) blown Replace fuse and check for
Flasher unit faulty short
Hazard switch faulty Check flasher unit
Hazard relay faulty Check switch
Wiring or ground faulty Replace relay
Repair if necessary
Flasher rate too slow or too fast Lamps' wattages are smaller or larger than Replace lamps
specified
Defective flasher unit Check flasher unit
Back up lamps do not light up No.5 fuse (10A) blown Replace fuse and check for
Back up lamp switch faulty short
Repair if necessary
Replace fuse and check for
Room lamp fuse (10A) blown
Room lamp does not light up short
Wiring or ground faulty
Repair if necessary
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AUDIO
CHART 1
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CHART 2
CHART 3
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CHART 4
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CHART 5
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CHART 6
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CHART 7
CHART 8
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CHART 9
CHART 10
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WINDSHIELD WIPER
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1. Wiper low and wiper high does not work.
2. When washer switch is on, wiper does not work.
POWER WINDOW
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1. No windows operate from the main switch on the driver's door.
2. Driver's side window does not operate.
3. Passenger's side window does not operate.

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POWER DOOR LOCK

1. Lock function works but unlock function does not interlock.
→ Since door unlock relay has failed, replace the door unlock relay.
2. Unlock function works but lock function does not interlock.
→ Since door lock relay has failed, replace the door lock relay.
3. When passenger side knob is controlled, all doors interlock, but when driver side knob is controlled, all doors do not
interlock.
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4. When passenger side knob is controlled. All doors interlock. But when the driver side knob is controlled, all doors
do not interlock.
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5. Both sides do not interlock either.

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KEYLESS ENTRY & BURGLAR ALARM SYSTEM

1. Alarm does not work. (Hazard lamp works)
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2. When hood is opened inside the car like alarm test, horn does not work.
3. When door is opened inside the car like alarm test, horn does not work (If tailgate and hood is opened, alarm
works)
4. When tailgate is opened inside the car like alarm test, horn does not work.
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5. When the vehicle is locked by the transmitter, central door lock function works but hazard lamp doesn't blink.
6. Engine does not start, when the alarm released condition.

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7. Central door lock function works, but keyless entry system does not work.
Body Electrical System > General Information > Specifications

SPECIFICATIONS
MULTIFUNCTION SWITCH
Items Specifications
Rated voltage DC 12 V
Operating temperature range -30°C ~ +80°C (-22 ~ +176°F)
Rated load
Dimmer & passing switch High : 15A (Lamp load)
Low : 10A (Lamp load)
Passing : 15A (Lamp load)
Lighting switch Lighting : 0.22±0.05A (Relay load)
Turn signal & lane change switch 6.6±0.5A (Lamp load)
Wiper & mist switch Low, High : 4A (Motor load)
Intermittent : 0.22±0.05A (Relay
load)
Lock : Max. 23A (Motor load)
Washer switch Mist : 4A (Motor load)
Variable intermittent volume switch 4A (Motor load)
Horn switch Max. 25mA
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1A (Relay load)
INSTRUMENTS AND WARNING SYSTEM

Warning lamps Bulb wattage (W) Color
Bulb type : 12V,
1.5W
Illumination White green
EL type : 47V, 470
Hz
High beam LED Blue
Low fuel LED Amber
Turn signal (LH,
LED Green
RH)
Battery (charge) LED Red
Oil pressure LED Red
Air bag Bulb (1.1W) Red
Parking brake LED Red
Seat belt LED Red
Check engine Bulb (1.1W) Amber
ABS Bulb (1.1W) Amber
Door ajar LED Red
Trunk lid open LED Amber
OD OFF LED Amber
INDICATORS AND GAUGE

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LIGHTING SYSTEM
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Items Bulb wattage (W)
60W /55W (High / Low
Head lamp
beam)
Front turn signal lamp 27W
Front position lamp 5W
Front fog lamp 27W
Side marker lamp 5W
Rear combination lamps
Tail/stop lamp 8W / 28W
Back up lamp 17W
Turn signal lamp 27W
Luggage lamp 5W
Room lamp 10W
Center high mounted stop lamp 17W
Map lamp 10W x 2
License plate lamp 5W
AUDIO
Items H210 H240, H260
Rated output Max. 20W x 2 Max. 20W x 4
Load impedance 4Ω x 4 4Ω x 4
Band AM/FM AM/FM
Tuning type PLL Synthesized type PLL Synthesized type
Dark current Max. 2mA Max. 2mA
AM : 530 ~ 1710KHZ/10 KHZ AM : 530 ~ 1710KHZ/10 KHZ
Frequency range / Channel FM : 87.9 ~ 107.9MHZ/200 FM : 87.9 ~ 107.9
KHZ MHZ/200KHZ
WINDSHIELD WIPER AND WASHER

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Wiper motor
Speed/current at 10kg·cm load test Low : 44~52 rpm/3.5A or less
(1.0 Nm, 0.7 lb·ft) High : 64~78 rpm/4.5A or less
Speed/current at 40kg·cm load test Low : 39~47 rpm/5.5A or less
(3.9 Nm, 2.9 lb·ft) High : 56~68 rpm/7.0A or less
Current when locking Low : 24A or less
High : 28A or less
Windshield washer
Motor type
DC ferrite magnet
Pump type
Centrifugal type
Current
3.8A
Discharge pressure
1.2 kg/cm² or more
Flow rate
1,320 cc/min. or more
Overload capacity (Continuous
operation)
60 sec. or less
With water
20 sec. or less
Without water
Body Electrical System > Audio > Components and Components Location
COMPONENTS
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Body Electrical System > Audio > Audio Unit > Components and Components Location
COMPONENTS
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Body Electrical System > Audio > Audio Unit > Repair procedures
REMOVAL AND INSTALLATION
1. Disconnect the negative battery terminal.
2. Remove the glove box.
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3. Disconnect the heater control cables under the glove box and lower crashpad.
4. Loosen the screws and remove the center facia panel.
5. Remove the audio mounting screws (4EA) and the audio system.
6. Installation is the reverse of removal.
INSPECTION
TAPE HEAD AND CAPSTAN CLEANING
1. To obtain optimum performance, clean the head, and capstan as often as necessary, depending on frequency of
use and tape cleanness.
2. To clean the tape head and capstan, use a cotton swab dipped in ordinary rubbing alcohol. Wipe the head and
capstan.
Body Electrical System > Audio > Speakers > Repair procedures
FRONT SPEAKER
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1. Remove the front door trim panel and front speaker. (see BD group - front door)

REAR SPEAKER
1. Remove the rear package tray or covering shelf trim. (see BD group - interior trim)
2. Remove the rear speaker.
INSPECTION
1. Check the speaker with an ohmmeter. If an ohmmeter indicates the correct impedance of the speaker when
checking between the speaker (+) and speaker (-) of the same channel, the speaker is ok.
2. If a clicking sound is emitted from the speaker when the ohmmeter is connected to the speaker terminals, the
speaker is ok.
Body Electrical System > Audio > Antenna > Repair procedures
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2. Remove the rear transverse trim and left side luggage rear trim.
3. Remove the antenna mounting nut and bolt.

Disconnect the wiring connector and the antenna feeder cable.
INSPECTION
1. Disconnect the connector from the antenna assembly.
2. Check if the battery voltage is measured between terminal 1 and 3 of harnessside at all time.
3. Check if the battery voltage is measured between terminal 1 and 2 of the harnessside when the ignition switch and
audio switch are turned on.
4. After connecting battery source to terminal 2 and 3 of the component side,check if the motor operates properly
(Antenna moves up.)
5. Check if the motor operates (antenna moves down) when terminal 2 is disconnectedfrom battery source.
Body Electrical System > Multifunction switch > Components and Components Location
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COMPONENTS
Body Electrical System > Multifunction switch > Multi Function Switch > Repair procedures
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• Never attempt to disassemble or repair the air bag module or clock spring. If faulty, replace it.
• Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace if a dent,
crack, deformation or rust are detected.
• The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do
not place anything on top of it.
• Do not expose the air bag module to temperatures over 93°C (200°F).
• After deployment of an air bag, replace the clock spring with a new one.
• Wear gloves and safety glasses when handling an air bag that has already been deployed.
• An undeployed air bag module should only be disposed of in accordance with the procedures mentioned in the
Restraints section.
• When you disconnect the air bag module-clock spring connector, take care not to apply excesive force to it.
• The removed air bag module should be stored in a clean, dry place.
• Prior to installing the clock spring, align the mating mark and "NEUTRAL" position indicator of the clock
spring, and, after turning the front wheels to the straight-ahead position, install the clock spring to the column
switch. If the mating mark of the clock spring is not properly aligned, the steering wheel may not completely
rotate during a turn, or the flat cable within the clock spring may be severed, obstructing normal operation of
the SRS and possibly leading to serious injury to the vehicle's driver. To inspect the clock spring, refer to the
Restraints section.
Prior to doing any further work after disconnection of the battery cable, wait at least 30
seconds.
2. Remove the air bag module mounting bolts (2EA) with an asterix wrench. (Tor-x socket)
Disconnect the horn connector and the air bag module connector, and remove the air bag module.
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3. Remove the steering wheel after removing a nut.
4. Remove the steering column upper and lower shrouds using a phillips screwdriver.
5. Remove the multifunction switch assembly mounting screws (3EA) and multifunction switch assembly after
removal of the connectors.
INSPECTION
LIGHTING SWITCH INSPECTION
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LIGHTING SWITCH (CONNECTOR NO. : M10-2)
DIMMER AND PASSING SWITCH (CONNECTOR NO. : M10-2)
TURN SIGNAL SWITCH (CONNECTOR NO. : M10-2)
WIPER AND WASHER SWITCH INSPECTION
WIPER SWITCH (CONNECTOR NO. : M10-1)

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WASHER SWITCH (CONNECTOR NO. : M10-1)
Body Electrical System > Horn > Components and Components Location
COMPONENTS
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Body Electrical System > Horn > Horn > Repair procedures
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1. Remove the bolt and disconnect the horn connector, then remove the horn.
INSPECTION
1. Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
2. The horn should make a sound. If the horn fails to make a sound, replace it.
ADJUSTMENT
After adjustment, apply a small amount of paint around the screw head to keep it from loosening.
Body Electrical System > Keyless Entry And > Schematic Diagrams
ETACS MODULE INPUT SIGNAL TEST
1. Disconnect the wire connectors(B) from the ETACS module(A).
2. Inspect the connectors(B) on wire harness side as shown in the below.
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Terminals No. Test condition Standard value
Door switch "ON" (Door opened) Below 1Ω
38-35 (GND)
Door switch "OFF" (Door closed) 1MΩ or higher
Luggage compartment door switch "ON"
Below 1Ω
(Luggage compartment door opened)
40-35 (GND)
Luggage compartment door switch "OFF"
1MΩ or higher
(Luggage compartment door closed)
Engine hood switch "ON" (Engine hood opened) Below 1Ω
34-35 (GND)
Engine hood switch "OFF" (Engine hood closed) 1MΩ or higher
Driver's door switch "ON" (Driver's door opened) Below 1Ω
37-35 (GND)
Driver's door switch "OFF" (Driver's door closed) 1MΩ or higher
Assist door switch "ON" (Assist door opened) Below 1Ω
36-35 (GND)
Assist door switch "OFF" (Assist door closed) 1MΩ or higher
Door warning switch "ON" (Key inserted) Battery voltage
39-35 (GND)
Door warning switch "OFF" (Key removed) Below 1V
Trunk key unlock switch "ON" (Trunk lid is unlocked with key) Below 1Ω
42-35 (GND)
Trunk key unlock switch "OFF" 1MΩ or higher
27-35 (GND) Always Battery voltage
17-35 (GND) Ignition switch is turned to "ON" position Battery voltage
Driver's door lock switch "ON" (Driver's door unlock detection) Below 1Ω
31-35 (GND)
Driver's door lock switch "OFF" (Driver's door lock detection) 1MΩ or higher
Assist door lock switch "ON" (Assist door unlock detection) Below 1Ω
30-35 (GND)
Assist door lock switch "OFF" (Assist door lock detection) 1MΩ or higher
Rear door lock switch "ON" (Rear door unlock detection) Below 1Ω
32-35 (GND)
Rear door lock switch "OFF" (Rear door lock detection) 1MΩ or higher
14-35 (GND) Always Battery voltage
13-35 (GND) Engine Start Battery voltage
35 (GND) - Body
Always Below 1Ω
ground
3-35 (GND) Burglar alarm horn operation ON
Driver's door key unlock switch "ON"
5-35 (GND) Below 1Ω
(Driver's door is unlocked with key)
Assist door and tailgate key unlock switch "ON"
11-35 (GND) Below 1Ω
(Assist door and tailgate are unlocked with key)
Body Electrical System > Keyless Entry And > Description and Operation
DESCRIPTION
Page 46 of 135
BURGLAR ALARM SYSTEM
• A door is forced open.
• A door is unlocked without using the transmitter.
• The trunk lid is opened without using the key.
• The hood is opened.
• The engine starter circuit and battery circuit are bypassed by breaking the ignition switch.
KEYLESS ENTRY SYSTEM
ANTI-THEFT FUNCTION
1. ARM FUNCTION
Pressing the remote key lock button will result in a 0.5-second pulse issued to lock all doors.
Pressing the remote keypad unlock button once will result in a 0.5-second unlock pulse issued to unlock all
doors.
As part of the arming sequence the alarm first enters a pre-armed state before falling into the armed state. During
this pre-armed state alarm triggers are ignored. Pre-armed state can be reached from the alarmed state, the start
inhibit state or the disarmed state. Pre-Arming of the alarm can be achieved by a press of the lock button on the
remote key.
In the pre-armed state the visible and audible warnings are disabled.
This system enters the armed state if it is in the pre-armed state and, after 0.6 sec, check actuator lock and each
door, hood and tail gate close, and no door warning switch (no key in ignition).
On entering the arm state, a single flash of the hazard lamps is given, period of cycle 2 second, duty rate 50%.
If TX lock signal is received when a door, tail gate or hood is open, then lock output is given and a flash of
hazard is not given.
After the armed state is entered, if a lock signal is received then a single flash of the hazard lamps is given, period
of cycle 2 second, duty rate 50%.
The armed state cannot be reached by locking the car with the keys.
Time specification
T1 : 0.5 sec.
T2 : Max. 2 sec.
T3 : 1.0 ± 0.2 sec.
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2. DISARM FUNCTION
Disarming can be performed while the alarm is armed, or alarming, or after alarming. The alarm can be disarmed
by the following methods :
A. Pressing the unlock button on the TX key. The hazard lamps shall be flashed twice for 1sec period (of cycle),
50% duty rate.
B. If door warning switch is on, IGN1 and IGN2 are on in arm state, then arm state should be immediately
cancelled. This means that the driver is inside the vehicle before pushing TX lock, so system should not arm.
In the disarm state the visible and audible warnings are disabled and start is enabled.
In the disarm state, if TX key unlock command is received, then the hazard lamps shall be flashed twice for
period of cycle 1 sec, 50% duty rate.
Disarm state cannot be reached using the door locks by key.
Time specification
T1, T2 : 0.5 ± 0.1 sec.
3. ALARM FUNCTION
Once armed, should any door, hood or the tailgate be opened, then.
A. Start relay drive output is disabled, so starting is inhibited
B. Audible (horn) and visual (hazard lamp) warnings are issued, for three cycles, each cycle 27±2 sec. duration
on, 10±1 sec. off. The horn warning is continuously occurring during the on period. The hazard lamps operate
with 1 sec period, 50 % duty rate during the on period
The alarm is given in the case where a door is opened with a key.
After this time, the system maintains the start inhibit state, where no audible and visual warnings are issued but
engine starting is not possible.
Time specification
T1 : 27 ± 2 sec.
T2 : 10 ± 1sec.
T3 : 0.4~0.5 sec.
4. OPERATION DURING ALARM CONDITIONS
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(1) Cancelling audible alarm with the remote transmitter.
CASE 1 : Door closed
During or after alarming and then closing all doors and a TX lock signal is received Then
A. The lock command is executed with 0.5 sec. ON
B. Horn and start inhibition are OFF
C. Hazard lamp is flashed one time (period : 2 sec., duty: 50%, within 2 sec.)
D. The state goes to arming mode (after a lock state check)
E. The start is enabled
Time specification
T1 : 0.5 sec.
T2 : 1.0 ± 0.2 sec.
CASE 2 : Door Open
During or after alarming, with a door open and a TX lock signal is received Then
A. The lock command is executed with 0.5 sec. ON
B. Horn is disabled and start is enabled after confirmation of actuator lock
At this time, when the door is closed,
A. Hazard lamp is flashed one time (period : 2 sec., duty 50%)
B. The state goes to arming mode
Time specification
T1 : 0.5 sec.
T2 : 1.0 ± 0.2 sec.
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(2) New alarm conditions
Second alarm condition during alarming.
When another alarm occurs during alarming, the starting is disabled, and the alarm continues to sound for the
remained time of warning signal. The alarm continues to sound after the second alarm condition is removed.
New alarm condition occurs after alarming (with all entrances closed)
If any entrance is opened again then
A. The horn is ON 3 times
B. Start is disabled
C. Hazard lamps flash during the ON time of horn
New alarm condition occur after alarming (with any entrance open).
If another entrance is opened, the ETACS module keeps start disabled and there is no horn output.
(3) Key operation during alarm

After the alarm state or start inhibit state are entered, if door warning switch on (key in ignition) &IGN 2 ON,
if IGN 2 state is changed to OFF within 30sec, remain in alarm state.
(4) Disarming using the key
During alarming, in case that door warning switch (key in) is ON and then IGN1 and IGN2 are both ON for
30 sec continuously, the alarm is cancelled, and the system enters the disarm state.
After alarming, in case that door warning switch (key in) is ON and then IGN1 and IGN2 are both ON for
30 sec continuously, the alarm is cancelled, and the system enters the disarm state.
5. ALARM STATE IN POWER DOWN

If the battery is disconnected to the ETACS module in the following states :
A. Alarm
B. After alarming
Upon restoring the battery, the alarm state shall be entered and the alarm cycle shall restarted (timer reset to 0).
Upon restoring the battery, the alarm state shall be entered and the alarm cycle shall restart (timer reset to 0).
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6. ALARM HOLD MODE
(1) In case of opening the trunk by trunk unlock switch during arm state, the alarming is hold.
When received transmitter (TX) trunk signal in arm state, trunk open by output trunk lid open relay signal for
500ms and then holding alarm.
But the door and hood except trunk is still in the arm state.
(2) Trunk is going to the arm state just case trunk is still closed for 2 sec.
T1 : Max. 0.2 sec., T2 : 2 sec.
Body Electrical System > Keyless Entry And > Components and Components Location
COMPONENTS
Page 51 of 135
Body Electrical System > Keyless Entry And > Repair procedures
INSPECTION
FRONT DOOR LOCK ACTUATOR INSPECTION
1. Remove the front door trim panel. (see BD group-front door)
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2. Disconnect the 4P connector from the actuator.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
REAR DOOR LOCK ACTUATOR INSPECTION

1. Remove the rear door trim panel. (see BD group-rear door)
FRONT DOOR LOCK SWITCH INSPECTION

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3. Check for continuity between the terminals in each switch position according to the table.
REAR DOOR LOCK SWITCH INSPECTION

DOOR SWITCH INSPECTION

Remove the door switch and check for continuity between the terminals.
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TAILGATE LOCK ACTUATOR INSPECTION (3 DOOR)

1. Remove the tailgate trim panel. (see BD group-tailgate)
TRUNK LID SWITCH INSPECTION (4DOOR)

2. After opening the trunk, disconnect the connector from the rear harness.
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3. Check for continuity between the terminal and body while pushing the rod.
Switch rod condition Continuity
Push (OFF) Non-conductive (∞Ω)
Released (ON) Conductive (0Ω)
TAILGATE SWITCH INSPECTION (3 DOOR)

1. Remove the tailgate trim panel. (see BD group-tailgate)
2. Remove the tailgate latch after removing 3 bolts and disconnect the 1P connector from the tailgate switch.
3. Check for continuity between the terminal and ground according to the table.
HOOD SWITCH INSPECTION

1. Disconnect the 1P connector from the hood switch.
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2. Check for continuity between the terminal and ground according to the table.
DOOR WARNING SWITCH INSPECTION

1. Remove the driver's crash pad lower panel. (see BD group-crash pad)
2. Disconnect the 2P connector from the door warning switch.
3. Check for continuity between the terminals in each position according to the table.
BURGLAR ALARM HORN INSPECTION

1. Remove the horn after removing a bolt and disconnect the 2P connector from the horn.
2. Test the horn by connecting battery power to terminal 1 and ground terminal 2.
The horn should make a sound. If the horn fails to make a sound replace it.
Body Electrical System > Keyless Entry And > Transmitter > Repair procedures
Page 57 of 135
INSPECTION
1. Check that the red light flickers when the door lock or unlock button is pressed on the transmitter.
2. Remove the battery and check voltage if the red light doesn't flicker.
Standard voltage : 3V
3. Replace the transmitter battery with a new one, if voltage is below 3V then try to lock and unlock the doors with
the transmitter by pressing the lock or unlock button five or six times.
4. If the doors lock and unlock, the transmitter is O.K, but if the doors don't lock and unlock, register the
transmitter code, then try to lock and unlock the doors (See page BE-31)
5. If the doors lock and unlock, the transmitter is O.K, but if the doors don't lock and unlock, replace the
transmitter.
TRANSMITTER CODE REGISTRATION

1. To register transmitter code, first connect keyless adapter (09900-21300) to DLC(Data Link Connector) cable
of hi-scan as shown in the illustration.
2. After connecting keyless adapter to the multi purpose check connector (10pins) beside data link connector in
driver side crash pad lower panel, turn the power on hi-scan.
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3. Select the vehicle model and then do "CODE SAVING".
4. After selecting "CODE SAVING" menu, button "ENTER" key, then the screen will be shown as below.
5. After removing the ignition key from key cylinder, push "ENTER" key to proceed to the next mode for code
saving.
6. Follow steps 1 to 3 and then code saving is completed.

7. Disconnect keyless adapter (09900-21300) from DLC cable and then proceed to self-diagnosis with DLC cable
connected.
Body Electrical System > ETACS (Electronic Time > Description and Operation
DESCRIPTION
ETACS module receives various input switch signals,
and controls time and alarm such as intermittent wiper
timer, washer timer, rear defogger timer, seat belts
warning, decayed out room lamp, central door lock,
ignition key reminder, power window timer, door
warning, tail lamp auto cut, crash door unlock and
keyless entry & burglar alarm automatically.
Page 59 of 135
Body Electrical System > ETACS (Electronic Time > Specifications
SPECIFICATIONS
Rated voltage DC 12V
Operating voltage DC 9 ~ 16V
Operating temperature -30°C ~ 80°C
Insulation resistance 100MΩ or more
DC 12V, 200mA (Inductance

load)
Rated load load)
Horn relay DC 12V, 200mA (Inductance
Chime bell load)
Rear defogger relay DC 12V, 200mA (Inductance
Hazard lamp relay load)
Tail lamp relay DC 12V, 200mA (Inductance
Seat belt warning indicator load)
Room lamp DC 12V, 1.2W (Lamp load)
Door lock relay DC 12V, 10W (Lamp load)
Door unlock relay DC 12V, 200mA (Inductance
Burglar alarm relay load)
load)
load)
Body Electrical System > ETACS (Electronic Time > ETACS Module > Schematic Diagrams
CIRCUIT DIAGRAM
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1. Disconnect the wire connectors(B) from the ETACS module(A).
2. Inspect the connectors(B) on wire harness side as shown in the below.
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Terminal Terminal
Connection Connection
No. No.
1 Hazard lamp (LH) 22 Door lock relay
2 Room lamp 23 Seat belt switch
3 Horn 24 Alternator "L"
4 Wiper relay 25 Speed sensor
5 Driver door key unlock switch 26 Crash sensor
6 Burglar alarm relay 27 B+
7 Rear defogger relay 28 Rear defogger switch
8 D.R.L 29 Washer switch
9 Tail lamp relay 30 Assist door lock switch
10 Seat belt warning lamp 31 Driver door lock switch
11 Assist & tailgate key unlock switch 32 Rear & tailgate lock switch
12 Intermittent wiper volume switch 33 Tail lamp switch
13 IGN1 34 Hood switch
14 B+ 35 Ground
15 Hazard lamp (RH) 36 Assist door switch
16 Door unlock relay 37 Driver door switch
17 IGN2 38 All doors switch
18 Code saving 39 Door warning switch
Trunk switch (4door)/ Tailgate switch
19 Chime bell 40
(3door)
20 Power window relay 41 Intermittent wiper switch
21 Driver door unlock relay 42 Trunk key unlock switch (4door)

Pin
Input signal name Test condition Desired result
No.
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Check for voltage to ground;
13 IGN1 Ignition switch ON or START
There should be battery voltage
17 IGN2 Ignition switch ON
24 Alternator "L" Engine start condition
39 Door warning switch Key is inserted into the ignition switch
Check for continuity to ground;
38 All door switch One of all doors is opened
There should be continuity
37 Driver's door switch Driver's door open
36 Assist door switch Assist door open
32 Rear door lock switch One of rear doors is unlock
Trunk switch (4door) / Trunk open (4door) / Check for continuity to ground;
40
Tailgate switch (3door) Tailgate open (3door) There should be continuity
Trunk key unlock switch Key is inserted into the trunk key cylinder Check for continuity to ground;
42
(4door) and turned There should be continuity
34 Hood switch Hood open
29 Washer switch Washer switch ON
41 Intermittent wiper switch INT. wiper switch ON
Intermittent wiper volume Resistance should vary from 0Ω
12 INT. wiper volume switch ON
switch to 50kΩ
28 Rear defogger switch Rear defogger switch ON
33 Tail lamp switch Tail lamp switch ON
23 Seat belt switch Seat belt is unbuckled
18 Code saving tool Code save signal There should be open at unused
Check for voltage to ground ;
14, 27 Battery (+) Constant
Check for continuity to ground ;
35 Ground Constant
31 Driver's door lock switch Driver's door is unlock
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30 Assist door lock switch Assist door is unlock
Driver's door key unlock Check for continuity to ground ;
5 Driver's door is unlock with key
switch There should be continuity
Assist & tailgate unlock Assist door and tailgate are unlock with Check for continuity to ground :
11
switch key There should be continuity
Check for voltage to ground ;
26 Air bag signal Ignition switch ON
There should be about 5V
Body Electrical System > ETACS (Electronic Time > ETACS Module > Repair procedures
1. Disconnect the negative(-) battery terminal.
2. Remove the 2 screws and 2 bolts holding the driver's crash pad lower panel.
3. Disconnect the hood release cable and the data link connector from beneath the driver's crash pad lower panel.
4. Remove the ETACS module from the bracket after removing bolts.
INSPECTION
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1. VEHICLE SPEED SENSING INTERMITTENT WIPER
Time specification
T1 : Max. 0.5sec.
T2 : 0.6~0.7 sec. (Time of wiper motor 1 rotation)
T3 : At vehicle speed : 0km/h.
2.6±0.7 sec. (VR=0kΩ)~18.0±1sec. (VR=50kΩ)
At vehicle speed = 100km/h or more.
1.0±0.2sec. (VR=0kΩ)~10.0±1 sec. (VR=50kΩ)
2. WASHER
A. Time specification
T1 : 0.3 sec.
T2 : 0.6~0.8 sec.
T3 : 0.2~0.6 sec.
B. Time specification
T1 : 0.3 sec.
T2 : 2.5~3.8 sec.
T3 : 0.6 sec. or more
C. This function should be operated preferentially even though the variable intermittent wiper is operating.
3. DEFOGGER TIMER (Including Outside Mirror Demister)
(1) After ALT "L" ON, if the defogger is switched ON, the defogger output is ON for 20 minutes duration.
(2) If the defogger switch is pressed again, or if the ignition is switched OFF during this time, the defogger output
is OFF.
T1 : 20 ± 1min.
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4. SEAT BELT WARNING TIMER
(1) Since the ignition is switched ON, the seat belt warning indicator is illuminated infinitely (with period : 0.6
sec., duty rate : 50%) and the chime bell is sounded (with period : 0.9 sec., duty rate : 50%) for total time 6
seconds.
(2) If the ignition is swithced off during the indicator and the chime bell output, the indicator and the chime bell
are switched OFF.
If the seat belt is fastened during the indicator and the chime bell output, the indicator and the chime bell are
switched OFF immediately.
(3) When the ignition is already switched ON, if the seat belt is not fastened, the chime bell is sounded for 6
second and the warning indicator is illuminated infinitely.
T1 : 6±1 sec., T2 : 0.45 ± 0.1 sec.,

T3 : 0.3 ± 0.1 sec.
5. DECAYED ROOM LAMP & KEYLESS UNLOCK TIMER
(1) When the first door (driver's or assist) is opened, the room lamp shall brighten. When the last door is closed,
the room lamp will drop to 75% intensity, then fade out over 5-6 seconds.
(2) If the door switch is ON for less than 0.1 sec., then no illumination occurs.
(3) The fade resolution is over 32 steps.
(4) The room lamp must not flicker during fade operation, if the ignition is switched ON.
(5) With keyless UNLOCK, when the door is closed, the room lamp is turned ON, then OFF after about 30
seconds. While the room lamp is ON due to keyless UNLOCK, if another UNLOCK is received, the room
lamp is again ON for 30 seconds.
While the room lamp is ON, If the door is opened, the lamp is continued to ON. If the door is closed, the
lamp follows as the above step 1.
If keyless LOCK (ARM state) is received during fade out, the room lamp is switched off immediately.
T1 : 5.5 ± 0.5 sec., T2 : 30 ± 3 sec.

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6. CENTRAL DOOR LOCK/UNLOCK
(1) If transmitter(TX) lock or key lock signal is received, all door lock output is ON.
(2) With driver door lock state, if TX unlock or key unlock signal is received, only driver door unlock output is
ON.
(3) Within 4 sec. since final unlock signal, if TX unlock or key unlock signal is received again, all doors unlock
output is ON at driver door unlock state.
If the time (4 sec.) elapse, only driver door unlock output is ON.
(4) Using safety knob, possible to central door lock/unlock.
(5) Door key unlock switch is applied to driver door, assist door and tailgate.
T1 : 0.5 ± 0.1 sec.

T2 : Max. 4 sec.
T3 : Min. 4 sec.
7. IGNITION KEY REMINDER
T1,T3 : 0.5 sec., T2 : 1 sec., T4 : Max.0.5 sec.

8. POWER WINDOW TIMER
(1) When the ignition is switched ON, the power window relay output is turned ON.
(2) When the ignition is switched OFF, the power window output is maintained ON for 30 seconds and then
turned OFF.
(3) With the state of step 2, if the driver's door or assist door is opened, the output shall be turned OFF
immediately.
T1 : 30 ± 3 sec.
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9. DOOR OPEN WARNING
(1) If the key is in the ignition key cylinder and the driver's door is opened, the chime bell sounds continually
(period:0.9 sec. Duty rate:50%).
(2) If the door is closed or the key is removed, the chime stops immediately.
T1,T2 : 0.45 ± 0.1 sec.

10. TAIL LAMP AUTO CUT
(1) When the tail lamp is switched ON, if the ignition is switched OFF and the driver's door is opened, the tail
lamp should be automatically OFF.
(2) With the ignition switched ON, if the driver's door is opened and the ignition is switched OFF, the tail lamp
should be automatically OFF.
(3) When the tail lamp is cut automatically, if the tail lamp switch is turned OFF and ON, the tail lamp is
illuminated and auto cut function is cancelled.
11. CRASH DOOR UNLOCK

(1) With the ignition turned ON, if the air bag is deployed, a crash signal is received and send an UNLOCK
output to all doors UNLOCK.
(2) After UNLOCK output, when LOCK is set, UNLOCK pulse is output for 5 second period again.
T1 : 200 msec.
T2 : 40 msec.
T3 : 5±0.5sec.
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12. TX LOCK TWO TIMES FUNCTION
T1 : 0.5 ± 0.1 sec.

T2 : 1 ± 0.2 sec.
T3 : 0.05 sec.
T4 : Max. 4 sec.
T5 : Min. 4 sec.
13. PANIC ALARM
(1) If panic switch is ON, horn output keeps ON for 30 sec and if panic switch is ON again, horn output is
OFF.
(2) Panic mode is not affected at arm or disarm state.
(3) While panic is operating, arm or disarm function operates.
T1 : 30 ± 1 sec.
Body Electrical System > Fuses And Relays > Components and Components Location
COMPONENTS
Page 69 of 135
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Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Components and
Components Location
COMPONENTS
Page 71 of 135
Page 72 of 135
Body Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Repair procedures
INSPECTION
POWER RELAY TEST (TYPE A)
1. There should be continuity between the No.3 and No.4 terminals when power and ground are connected to the
No.1 and No.2 terminals.
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2. There should be no continuity between the No.3 and No.4 terminals when power is disconnected.
POWER RELAY TEST (TYPE B)

POWER RELAY TEST (TYPE C)

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2. There should be continuity between the No.1 and No.4 terminals when power is disconnected.
Body Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) > Components
and Components Location
COMPONENTS
Page 75 of 135
Page 76 of 135
Body Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) > Repair
procedures
INSPECTION
POWER RELAY TEST (TYPE A)
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2. There should be continuity between the No.1 and No.4 terminals when power is disconnected.
POWER RELAY TEST (TYPE B)

FUSE INSPECTION
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
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3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew
and completely eliminate the problem before installing a new fuse.
Never use a fuse of higher capacity than specified.
FUSES
1. Fuse blown due to over-current.
Prior to replacing the fuse with a new one, check the circuit for a short and the related parts for abnormal
conditions. Only after the correction of a short or replacement of abnormal parts, should a fuse with the same
ampere rating be installed.
2. Fuse blown due to repeated on-off current.

Normally, this type of problem occurs after a fairly long period of use, and is less frequent than #1 above. In this
case, you may simply replace with a new fuse of the same capacity.
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A blade type fuse is identified by the numbered value in amperes. If the fuse is blown, be sure to replace a
fuse with the same ampere rating.If a fuse of higher capacity than specified is used, parts may be damaged
and a danger of fire exists. To remove or insert a fuse, use the fuse puller in the fuse box.
Body Electrical System > Indicators And Gauges > Components and Components Location
COMPONENTS
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Body Electrical System > Indicators And Gauges > Instrument Cluster > Schematic Diagrams
CIRCUIT DIAGRAM
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Body Electrical System > Indicators And Gauges > Instrument Cluster > Components and Components
Location
COMPONENTS
Page 82 of 135
Body Electrical System > Indicators And Gauges > Instrument Cluster > Repair procedures
Page 83 of 135
2. Remove the cluster facia panel.
3. Remove the cluster from the housing after removing screws.
4. Disconnect the wire connectors from the cluster.

INSPECTION
INVERTER (WITH EL TYPE CLUSTER)
The inverter is located in the instrument cluster and it converts the direct current (DC) into the alternating current
(AC).
Illumination power applied to inverter in the cluster is converted into the alternating current (AC), which is supplied
EL (Electroluminescent Lamp) sheets to be illuminated.
1. Remove the front cover from the cluster and disconnect wire lead connector from EL sheet.
2. Apply battery voltage (DC 13.5V) to the inverter in the cluster and measure the output voltage between terminal
1 and 2.
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3. Also measure the output frequency between the terminals.
4. If the value is not as shown in the table, replace the inverter.

EL sheet
Input voltage Input current Output voltage Output frequency
luminosity
DC 13.5V ±1% DC 30mA ±10% 40 Vrms ±20% 520Hz ±15% 11cd/m² ±8%
If the inverter is normal, connect the EL and inverter, supply power to the cluster, and check the EL
illuminates at the dark.
If EL illumination is too dark, should be replaced.
SPEEDOMETER
1. Adjust the pressure of the tires to the specified level.

2. Drive the vehicle onto a speedometer tester. Use wheel chocks as appropriate.
3. Check if the speedometer indicator range is within the standard values.
Do not operate the clutch suddenly or increase/ decrease speed rapidly while
testing.
Tire wear and tire over or under inflation will increase the indication error.
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Velocity
20 40 60 80 100 120
(km/h)
Tolerance
±2.4 ±2.4 ±2.4 ±2.7 ±2.7 ±3.2
(km/h)
Velocity
140 160 180 200 Area
(km/h)
Tolerance Only
±3.2 ±3.7 ±3.7 ±4.0
(km/h) CANADA
Velocity
10 20 40 60 80 100 120 Area
(MPH)
Tolerance Only
±1.5 ±1.5 ±1.5 ±1.7 ±1.7 ±1.7 ±1.7
(MPH) U.S.A
TACHOMETER
1. Connect the scan tool to the diagnostic link connector or install a tachometer.
2. With the engine started, compare the readings of the tester with that of the tachometer. Replace the tachometer if
the tolerance is exceeded.
1. Reversing the connections of the tachometer will damage the transistor and diodes inside.
2. When removing or installing the tachometer, be careful not to drop it or subject it to severe shock.
Revolution
1,000 2,000 3,000 4,000 5,000 6,000 7,000
(RPM)
Tolerance
±100 ±125 ±150 ±170 ±200 ±240 ±280
(RPM)
FUEL GAUGE
OPERATION CHECK
1. Disconnect the fuel sender connector from the fuel sender.
2. Connect a 3.4 watt, 12V test bulb to terminals 2 and 3 on the wire harness side connector.
3. Turn the ignition switch to the ON, and then check that the bulb lights up and the fuel gauge needle moves to full.
FUEL SENDER
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1. Using an ohmmeter, measure the resistance between terminals 2 and 3 at each float level.
2. Also check that the resistance changes smoothly when the float is moved from "E" to "F".
Position Gauge angle (°) Resistance (Ω)
Sender (E) -4.5 ± 4.0 200
Gauge (E) 0 ± 4.0 184
Warning lamp 4.2 ± 4.0 170
1/2 50 ± 4.0 66
Gauge (F) 100 ± 4.0 15
Sender (F) 104.5 ± 4.0 8
3. If the resistance is unsatisfied, replace the fuel sender as an assembly.
After completing this test, wipe the sender dry and reinstall it in the fuel
tank.
ENGINE COOLANT TEMPERATURE GAUGE

1. Disconnect the wiring connector from the engine coolant temperature sender in the engine compartment.
2. Turn the ignition switch ON. Check that the gauge needle indicates cool. Turn the ignition switch OFF.
3. Connect a 12V, 3.4 watt test bulb between the harness side connector and ground.
4. Turn the ignition switch ON.

5. Verify that the test bulb flashes and that the indicator moves to HOT.
If operation is not as specified, replace the engine coolant temperature gauge. Then recheck the system.
ENGINE COOLANT TEMPERATURE SENDER
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1. Using an ohmmeter, measure the resistance between the terminal 2 and ground.
2. If the resistance value is not as shown in the table, replace the temperature sender.
Temperature (°C) 55 85 110 125
Gauge angle (°) 0 43 ± 4 43 ± 4 95 ± 4
Resistance (Ω) 160.3 70.3 27.9 18.6
OIL PRESSURE SWITCH

1. Check that there is continuity between the terminal and ground with the engine off.
2. Check that there is no continuity between the terminal and ground with the engine running.
3. If operation is not as specified, replace the switch.
OIL PRESSURE WARNING LAMP

1. Disconnect the connector from the warning switch and ground the terminal on the wire harness side connector.
2. Turn the ignition switch ON. Check that the warning lamp lights up.If the warning lamp doesn't light, test the bulb
or inspect the wire harness.
BRAKE FLUID LEVEL WARNING SWITCH

1. Remove the connector from the switch located at the brake fluid reservoir.
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2. Verify that continuity exists between switch terminals 1 and 2 while pressing the switch (float) down with a rod.
BRAKE FLUID LEVEL WARNING LAMP

2. Release the parking brake.
3. Remove the connector from the brake fluid level warning switch.
4. Ground the connector at the harness side.
5. Verify that the warning lamp lights.
PARKING BRAKE SWITCH

The parking brake switch is a push type located under the parking brake lever. To adjust, move the switch mount up
and down with the parking brake lever released all the way.
1. Check that there is continuity between the terminal and switch body with the switch ON (Lever is pulled).
2. Check that there is no continuity between the terminal and switch bodywith the switch OFF (Lever is released).
If continuity is not as specified, replace the switch or inspect its ground connection.
DOOR SWITCH
Remove the door switch and check for continuity between the terminals.
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SEAT BELT SWITCH

1. Remove the connector from the switch.
2. Check for continuity between terminals.
Seat belt condition Continuity
Non-conductive
Fastened
(∞Ω)
Not fastened Conductive (Ω)
SEAT BELT WARNING LAMP

With the ignition switch turned ON, verify that the lamp glows.
Seat belt
Warning lamp
condition
Fastened OFF
Not fastened ON
Body Electrical System > Power Door Locks > Components and Components Location
COMPONENTS
Page 90 of 135
Body Electrical System > Power Door Locks > Power Door Lock Actuators > Repair procedures
INSPECTION
FRONT DOOR LOCK ACTUATOR INSPECTION
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REAR DOOR LOCK ACTUATOR INSPECTION

FRONT DOOR LOCK SWITCH INSPECTION

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REAR DOOR LOCK SWITCH INSPECTION

Body Electrical System > Power Door Locks > Power Door Lock Relay > Repair procedures
Page 93 of 135
INSPECTION
1. Remove the negative(-) battery terminal.
2. Remove the driver's side crash pad lower panel. (see BD group - crash pad)
3. Remove the door lock relay in the passenger compartment relay box, then check for continuity between the
terminals.
Body Electrical System > Power Door Mirrors > Components and Components Location
COMPONENTS
Page 94 of 135
Body Electrical System > Power Door Mirrors > Power out side mirror switch > Schematic Diagrams
CIRCUIT DIAGRAM
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Body Electrical System > Power Door Mirrors > Power out side mirror switch > Repair procedures
INSPECTION
1. Remove the power door mirror switch from the door trim panel.
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Body Electrical System > Power Door Mirrors > Power Door Mirror Actuator > Repair procedures
INSPECTION
1. Disconnect the power door mirror connector from the harness.
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2. Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly.
MIRROR HEATER INSPECTION
Body Electrical System > Power Windows > Components and Components Location
COMPONENTS
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Body Electrical System > Power Windows > Power Window Motor > Repair procedures
INSPECTION
FRONT POWER WINDOW MOTOR INSPECTION
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2. Disconnect the 2P connector from the motor.
3. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
REAR POWER WINDOW MOTOR INSPECTION

2. Disconnect the 2P connector from the motor.
3. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
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Body Electrical System > Power Windows > Power Window Switch > Schematic Diagrams
CIRCUIT DIAGRAM
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Body Electrical System > Power Windows > Power Window Switch > Repair procedures
INSPECTION
POWER WINDOW MAIN SWITCH
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1. Remove the power window main switch from the driver's door trim panel.
2. Check for continuity between the terminals.
POWER WINDOW LOCK SWITCH
POWER WINDOW SUB SWITCH

1. Remove the power window sub switch from the rear door trim panel.
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If continuity is not as specified in the table, replace the power window switch.
Body Electrical System > Rear Window Defogger > Components and Components Location
COMPONENTS
Page 104 of 135
Body Electrical System > Rear Window Defogger > Rear Window Defogger Printed Heater > Repair
procedures
INSPECTION
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Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure
on the tin foil, moving the tin foil along the grid line to check for open circuits.
1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center
point. If a voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window is
considered satisfactory.
2. If a heater line is burned out between the center point and (+) terminal, the voltmeter will indicate 12V.
3. If a heater line is burned out between the center point and (-) terminal, the voltmeter will indicate 0V.
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4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to
find a point where a voltage is generated or changes to 0V. The point where the voltage has changed is the open-
circuit point.
5. Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid line,
and between the same terminal and the center of one adjacent heater line. The section with a broken heater line
will have a resistance twice as that in other sections. In the affected section, move the test lead to a position
where the resistance sharply changes.
REPAIR OF BROKEN HEATER LINE

Prepare the following items :
1. Conductive paint.
2. Paint thinner.
3. Masking tape.
4. Silicone remover.
5. Using a thin brush :
Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as
shown. Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15
minutes apart. Remove the tape and allow sufficient time for drying before applying power. For a better finish,
scrape away excess deposits with a knife after the paint has completely dried. (Allow 24 hours).
Body Electrical System > Rear Window Defogger > Rear Window Defogger Switch > Repair
procedures
INSPECTION
1. Remove the negative(-) battery terminal.
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2. Disconnect the switch connector after removing the center facia panel.
3. Check for continuity between the terminals. If continuity is not as specified in the table, replace the defogger
switch.
Body Electrical System > Windshield Wiper/Washer > Components and Components Location
COMPONENTS
Page 108 of 135
Body Electrical System > Windshield Wiper/Washer > Windshield Wiper/Washer Switch > Repair
procedures
Page 109 of 135
2. Remove the 2 bolts and disconnect the airbag connector and the horn connector, then remove the airbag module.
Remove the horn pad only for vehicle without airbag.
3. Remove the steering wheel lock nut.
4. Remove the steering wheel with special tool (09561-11002).
Do not hammer on the steering wheel to remove it. Doing so may damage the collapsible
mechanism.
Page 110 of 135
5. Remove the steering column shroud after removing 3 screws.
6. Disconnect the wire connectors and remove the multi-function switch after removing the screws.
INSPECTION
WIPER SWITCH [M10-1]
WASHER SWITCH [M10-1]

Page 111 of 135
Body Electrical System > Windshield Wiper/Washer > Front Wiper Motor > Repair procedures
REMOVAL
1. Remove the windshield wiper arm and blade after removing a nut.
Tightening torque
28~32 Nm (280~320 kg·cm, 21~24 lb·ft)
2. Remove the weatherstrip and cowl top cover after removing 4 clips.
3. Remove the windshield wiper motor after removing 3 bolts.
Tightening torque
7~11 Nm (70~110 kg·cm, 5.1~8.0 lb·ft)
Page 112 of 135
4. Remove the wiper link mounting bolts and take out the wiper link assembly from the cowl top panel.
INSTALLATION
1. Install the wiper arm and blade to the specified position.
Specified position A B
Distance (mm) 25~35 25~35
2. Set the washer nozzle on the specified spray position.
INSPECTION
SPEED OPERATION CHECK
1. Remove the connector from the wiper motor.
2. Attach the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 3.
3. Check that the motor operates at low speed.
4. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 3.
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5. Check that the motor operates at high speed.
AUTOMATIC STOP OPERATION CHECK

1. Operate the motor at low speed using the stalk control.
2. Stop the motor operation anywhere except at the off position by disconnecting terminal 1
3. Connect terminals 1and 5.
5. Check that the motor stops running at the off position.
Body Electrical System > Windshield Wiper/Washer > Front Washer Motor > Repair procedures
2. Remove the front bumper cover. (see BD group - front bumper)
3. Remove the washer hose and the washer motor connector.
4. Remove the washer reservoir after removing 2 bolts.
INSPECTION
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1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
2. Connect positive (+) and negative (-) battery cables to terminals 2 and 1 respectively to see that the washer
motor runs and water sprays from the front nozzles.
3. Check that the motor operates normally.
Body Electrical System > Rear Wiper/Washer > Rear Wiper Motor > Components and Components
Location
COMPONENTS
Page 115 of 135
Body Electrical System > Rear Wiper/Washer > Rear Wiper Motor > Repair procedures
REMOVAL
1. Remove the tailgate trim panel.
Page 116 of 135
2. Remove the rear wiper arm after removing a nut.
Tightening torque
7~11 Nm (70~110 kg·cm, 5.1~8.0 lb·ft)
3. Remove a hexagonal nut after removing a pivot cover.
When installing cap & pad, the arrow mark should be indicated upward.
Tightening torque
10~14 Nm (100~140 kg·cm, 7.3~10.2 lb·ft)
4. Remove the rear wiper motor after removing 2 bolts and disconnect the wire connector.
Tightening torque
4~7 Nm (40~70 kg·cm, 2.9~5.1 lb·ft)
INSTALLATION
Page 117 of 135
1. Install the rear wiper arm and blade to the specified position.
Specified position A
Distance 150±10 mm
2. Set the rear washer nozzle on the specified spray position.
INSPECTION
1. Remove the connector from the rear wiper motor.
2. Connect battery positive (+) and negative (-) cables to terminals 1 and 4 respectively.
3. Check that the motor operates normally. Replace the motor if it operates abnormally.
Body Electrical System > Rear Wiper/Washer > Rear Washer Switch > Repair procedures
INSPECTION
1. Disconnect the connector from the rear wiper and washer switch.
Page 118 of 135
Body Electrical System > Rear Wiper/Washer > Rear Washer Motor > Repair procedures
INSPECTION
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
2. Connect positive(+) and negative(-) battery cables to terminals 2 and 3 respectively to see that the washer motor
runs and water is pumped.
3. Check that the motor operates normally.
Replace the motor if it operates abnormally.
Page 119 of 135
Body Electrical System > Lighting System > Components and Components Location
COMPONENTS
Page 120 of 135
Body Electrical System > Lighting System > Head Lamps > Repair procedures
Page 121 of 135
2. Remove the head lamp mounting bolts (2EA), then disconnect the lamp connectors.
3. Replace a burned-out bulb by a new one.
AIMING INSTRUCTIONS
HEAD LAMP AIMING
If there are any regulations pertinent to the aiming of head lamps in the area where the vehicle is to be used, adjust
so as to meet those requirements.
1. Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver, spare tire, and
tools.
2. The vehicle should be placed on a flat floor.
3. Draw vertical lines (Vertical lines passing through respective head lamp centers) and a horizontal line (Horizontal
line passing through center of head lamps) on the screen.
4. With the head lamp and battery in normal condition, aim the head lamps so the brightest portion falls on the
horizontal and vertical lines.
Make vertical and horizontal adjustments to the lower beam using the adjusting wheel.
FRONT FOG LAMP AIMING

The front fog lamps should be aimed as the same manner of the head lamps aiming.
With the front fog lamps and battery normal condition, aim the front fog lamps by turning the adjusting gear.
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HEAD LAMP AND FOG LAMP AIMING POINT

Page 123 of 135
1. Turn the low beam on without driver aboard.
The cut-off line should be projected in the allowable range (shaded region).
2. Turn the front fog lamp on without driver aboard.

The cut-off line should be projected in the allowable range (shaded region).
INSPECTION
HEAD LAMP RELAY
Page 124 of 135
1. Pull out the headlamp relay from the relay box in the passenger compartment.
Body Electrical System > Lighting System > Turn Signal Lamp > Repair procedures
2. Remove the 2 screws holding the rear combination lamp.
3. Disconnect the wire connector from the rear combination lamp.

4. Replace a burned-out bulb by a new one.

Page 125 of 135
Body Electrical System > Lighting System > Room Lamp > Repair procedures
2. Detach the lamp lens from the room lamp with a flat-tip screwdriver.
3. Remove the mounting screws (2EA) and disconnect the wire connector, then remove the room lamp assembly.
INSPECTION
Body Electrical System > Lighting System > Hazard Lamp Switch > Repair procedures
Page 126 of 135
INSPECTION
2. Remove the center facia panel with a flat-tip screwdriver, then disconnect the switch connector.
3. Operate the switch and check for continuity between terminals with an ohmmeter.
Body Electrical System > Lighting System > Flasher Unit > Repair procedures
INSPECTION
1. Remove the flasher unit from the passenger compartment relay box.
Page 127 of 135
3. Connect the two turn signal lamps in parallel to terminal 1. Check that the bulbs turn on and off.
The turn signal lamps should flash 60 to 120 times per minute. If one of the front or rear turn signal lamps
has an open circuit, the number of flashes will be more than 120 per minute. If operation is not as specified,
replace the flasher unit.
Body Electrical System > Lighting System > Rheostat > Repair procedures
INSPECTION
2. Detach the rheostat connector from the driver's crash pad panel.
3. Check for intensity. If the light intensity of the lamps changes smoothly without any flickering when the rheostat is
turned, it can be assumed that the rheostat is normal.
Body Electrical System > Lighting System > Front Fog Lamps > Repair procedures
2. Remove the front wheel guard.
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3. Remove the front fog lamp assembly after removing the screws, then disconnect the wire connector.
INSPECTION
FRONT FOG LAMP SWITCH
2. Remove the center facia panel with a flat-tip screwdriver, then disconnect the switch connector.
3. Operate the switch and check for continuity between terminals with an ohmmeter.
Body Electrical System > Lighting System > License Lamps > Repair procedures
1. Disconnect the negative (-) battery terminal.
2. Remove the tailgate trim.
Page 129 of 135
3. Remove the license plate lamp and disconnect the wire connector.
Body Electrical System > Lighting System > High Mounted stop lamp > Repair procedures
2. Remove the tailgate trim.
3. Remove the 5 bolts, disconnect the wire connector and then remove the center high mounted stop lamp.
Body Electrical System > Lighting System > Trunk Lamps > Repair procedures
2. Detach the luggage lamp assembly from the luggage side trim with a flat-tip screwdriver.
Page 130 of 135
INSPECTION
TRUNK ROOM LAMP SWITCH
2. After opening the trunk, disconnect the connector from the rear harness.
3. Check for continuity between the terminal and body while pushing the rod.
Switch rod condition Continuity
Pushed (OFF) Non-conductive (∞Ω)
Released (ON) Conductive (0Ω)
Body Electrical System > Daytime Running Lights > DRL Control Module > Schematic Diagrams
CIRCUIT DIAGRAM
Page 131 of 135
Body Electrical System > Daytime Running Lights > DRL Control Module > Repair procedures
INSPECTION
OPERATION CHECK
Check that the lights operate according to the following timing chart.
Page 132 of 135
INSPECT CIRCUITS FOR DAYTIME RUNNING LIGHT SYSTEM

1. Disconnect the wire connector to DRL module from engine compartment.
2. Inspect the connector on wire harness side as shown.
Tester connection Condition Specified condition

Head lamp switch OFF No continuity
5-Ground
Head lamp switch ON Continuity
6-Ground Constant Continuity
7-Ground Constant Battery voltage
Dimmer & passing
No voltage
switch ON
8-Ground
Dimmer & passing
Battery voltage
switch OFF
Engine Stop No voltage
3-Ground
Engine Running Battery voltage
Parking brake switch
Continuity
ON
4-Ground
Parking brake switch
No continuity
OFF
If circuit is not as specified, refer to schematic diagram and inspect short or circuits.
Body Electrical System > Ignition System > Ignition Switch > Repair procedures
Page 133 of 135
2. Remove the 2 bolts and disconnect the airbag connector and the horn connector, then remove the airbag module.
Remove the horn pad only for vehicle without airbag.
4. Remove the steering wheel with special tool (09561-11002).
Do not hammer on the steering wheel to remove it. Doing so may damage the collapsible
mechanism.
Page 134 of 135
5. Remove the steering column shroud after removing 3 screws.
6. Remove the screws holding the multi-function switch, then disconnect the wire connector.
Remove the multi-function switch assembly.
7. Remove the steering column mounting bolts.
8. Remove the key lock assembly from the steering column shaft. (see ST group)
INSPECTION
1. Remove the driver's side crash pad lower panel.
Page 135 of 135
2. Disconnect the ignition switch connector and the door warning switch connector under the steering column.

4. If continuity is not as specified, replace the switch.
Page 1 of 72
ACCENT(LC) > 2005 > G 1.5 SOHC > Brake System
Brake System > General Information > General Safety Information and Caution
PRECAUTION
• Care must be taken to replace each part properly as it could affect the performance of the brake system and
result in a driving hazard. Replace the parts with parts of the same part number or equivalent.
• It is very important to keep parts and the area clean when repairing the brake system.
Brake System > General Information > Special Service Tools

SPECIAL TOOLS
TOOL(Number and
ILLUSTRATION USE
name)
09581 ~ 11000 Spreading the front disc brake piston.
Piston expander
Brake System > General Information > Components and Components Location
Component Locating
Page 2 of 72
Brake System > General Information > Troubleshooting

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Page 3 of 72
Symptom Suspect Area Remedy
Lower pedal or spongy 1. Brake system (Fluid leaks) Correct
pedal 2. Brake system (Air in) Bleeding
3. Piston seals (Worn or damaged) Replace
4. Rear brake shoe clearance (Out of adjustment) Adjust
Replace
5. Master cylinder (Faulty)
Brake drag 1. Brake pedal freeplay (Minimal) Adjust
2. Parking brake lever travel (Out of adjustment) Adjust
3. Parking brake wire (Sticking) Correct
4. Rear brake shoe clearance (Out of adjustment) Adjust
Replace
5. Pad or lining (Cracked or distorted)
Replace
6. Piston (Stuck)
Replace
7. Piston (Frozen) Replace
8. Return spring (Faulty) Replace
9. Booster system (Vacuum leaks) Replace
10. Master cylinder (Faulty)
Brake pull 1. Pad or lining (Oily) Replace
2. Piston (Frozen) Replace
3. Disc (Scored) Replace
4. Pad or lining (Cracked or distorted) Replace
Hard pedal but brake 1. Brake system (Fluid leaks) Correct

inefficient 2. Brake system (Air in) Bleeding
3. Pad or lining (Worn) Replace
4. Pad or lining (Cracked or distorted) Replace
Adjust
5. Rear brake shoe clearance (Out of adjustment)
Replace
6. Pad or lining (Oily)
Replace
7. Pad or lining (Glazed) Replace
9. Booster system (Vacuum leaks)
Noise from brake 1. Pad or lining (Cracked or distorted) Replace
2. Installation bolt (Loosen) Retighten
4. Pad retainers (Loosen) Replace
Replace
5. Sliding pin (Worn)
Clearing
6. Pad or lining (Dirty)
Replace
7. Pad or lining (Glazed) Replace
8. Return spring (Faulty) Replace
9. Brake pad shim (Damage) Replace
10. Shoe hold-down spring (Damage)
Brake System > General Information > All Scheduled Maintenance Instructions
Operation and Leakage Check
Check all of the following items:
Page 4 of 72
Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes
do not work properly, check the brake booster. Replace the brake booster as
an assembly if it does not work properly or if there are signs of leakage.
Piston cup and pressure cup • Check brake operation by applying the brakes. Look for damage or signs of
inspection (B) fluid leakage. Replace the master cylinder as an assembly if the pedal does
not work properly or if there is damage or signs of fluid leakage.
• Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal
stroke.
Brake hoses (C ) Look for damage or signs of fluid leakage. Replace the brake hose with a new
one if it isdamaged or leaking.
Caliper piston seal and piston Check brake operation by applying the brakes.
boots (D) Look for damage or signs of fluid leakage. If the pedal does not work properly,
the brakes drag, or there is damage or signs of fluid leakage, disassemble and
inspect the brake caliper. Replace the boots and seals with new ones whenever
the brake caliper is disassembled.
Wheel cylinder piston cup and Check brake operation by applying the brakes.
dust cover (E) Look for damage or signs of fluid leakage. If the pedal does not work properly,
the brakes drag, or there is damage or signs of fluid leakage, replace the wheel
cylinder.
Page 5 of 72
Brake System > General Information > Repair procedures
Brake Pedal and Brake Switch Adjustment
Pedal Height
1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and back off the brake switch (B)
until it is no longer touching the brake pedal.
2. Lift up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the left-side center of
the pedal pad (D).
157.1 (+5, 0) mm [6.19 (+0.2, 0) in.]
3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from
the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod
depressed.
BRAKE SWITCH CLEARANCE
Pedal Free Play

Page 6 of 72
1. With the engine off, inspect the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand.
3~8 mm (0.11~0.31in.)
2. If the pedal free play is out of specification, adjust the brake switch (C). If the pedal free play is insufficient, it
may result in brake drag.
Parking brake check and adjustment
CHECK
1. Pull the parking brake lever (A) with 196 N (20 kgf, 44lbf) force to fully apply the parking brake. The parking
brake lever should be locked within the specified number of clicks (B)
Lever locked clicks: 6~7 clicks
2. Adjust the parking brake if the lever clicks are out of specification.
ADJUSTMENT
After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the brake
pedal several times to set the self-adjusting brake before adjusting the parking brake.
1. Block the front wheels, then raise the rear of the vehicle and make sure it is securely supported.
2. Pull the parking brake lever up one click.
3. Remove the console.

Page 7 of 72
4. Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.
5. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are
turned. Readjust if necessary.
6. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
7. Reinstall the console.
Brake System Bleeding
• Do not reuse the drained fluid.

• Always use Genuine DOT 3 or DOT 4 Brake Fluid. Using a non-Genuine DOT3 or DOT 4 brake fluid can
cause corrosion and decrease the life of the system.
• Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid.
• Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
• The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure
and checked after bleeding each brake caliper. Add fluid as required.
1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A).
2. Have someone slowly pump the brake pedal several times, then apply steady pressure.
3. Loosen the right-rear brake bleed screw to allow air to escape from the system. Then tighten the bleed screw
securely.
4. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the fluid.
Page 8 of 72
5. Refill the master cylinder reservoir to the MAX (upper) level line.
Front disc brake:
Rear drum brake:
Parking Brake Switch Test

1. Remove the rear console, and disconnect the connector (A) from the switch (B).
2. Check for continuity between the positive terminal and body ground:
A. With the brake lever up, there should be continuity.
B. With the brake lever down, there should be no continuity.
Page 9 of 72
Brake System > General Information > Specifications

SPECIFICATIONS
ITEMS SPECIFICATIONS
Master cylinder
Type Tandem type
I.D. mm (in.) 22.22 (0.875)
Fluid level warning sensor Provided
Brake booster
Type Vacuum type with single booster
Effective dia. mm (in.) 245.9 (9.7)
Boosting ratio 6.0 : 1
Proportioning valve
Cut-in pressure (Split point) 2.94 MPa (30 kg/cm², 427 psi)
Decompression ratio 0.27 : 1
Front brake
Type Floating type with ventilated disc
Disc O.D. mm (in.) 241 (9.49)
Disc thickness mm (in.) 19 (0.75)
Pad thickness mm (in.) 9 (0.35)
Cylinder I.D. mm (in.) 54 (2.13)
Rear brake (Drum)
Type Leading trailing drum
Drum I.D. mm (in.) 203.2 (8.0)
Wheel cylinder I.D. mm (in.) 17.78 (0.7)
Clearance adjustment Automatic
Parking brake
Actuation Mechanical brake acting on rear
Type wheels
Cable arrangement Lever
V type
Anti-lock Brake System (ABS)
HECU (HU+ECU)
ECU type Motor, valve relay integrated type
Motor power Max.150W
Accumulator volume 3.0cc
Inlet valve (Front/Rear) mm (in.) 0.5 (0.019)/0.315 (0.012)
Outlet valve (Front/Rear) mm (in.) 0.56 (0.022)/0.355 (0.014)
Wheel speed sensor

Output frequency 20 ~ 2,000Hz
Output voltage Min.130mVp.p
Internal resistance 1,385 ± 110Ω
Tone wheel teeth 44 teeth
Air gap mm (in.) 0.2 ~ 1.1 (0.008 ~ 0.043)
ABS & EBD warning lamp

Page 10 of 72
Type Active warning lamp module
Operating voltage 12V
Current 80mA
O.D = Outer Diameter

I.D = Inner Diameter
SERVICE STANDARD
ITEM STANDARD VALUE SERVICE LIMIT
Brake pedal height 157.1 (+5,0) mm [6.19 (+0.2, 0) in.]
Brake pedal stroke 125.6 mm (4.95 in.) or more
Stop lamp switch outer case to pedal 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.)
stopper clearance
Brake pedal free play 3~8 mm(0.11~0.31in.)
Booster push rod to master cylinder 0 (at 500mmHg vacuum)
piston clearance
Parking brake lever stroke when 6~7 clicks
lever assembly is pulled with
196N(20kg, 44lb force)
Front disc brake pad thickness 9 mm (0.354 in.) 2 mm (0.0787in.)
Front disc thickness(minimum) 19 mm (0.75 in.) 17 mm (0.67 in)
Front disc abrasion - 0.05 mm (0.002 in.)
Rear drum brake lining thickness 4.8mm (0.19 in.) 1 mm (0.04 in.)
Rear drum brake drum 180mm (7.09in.) 182 mm(7.17 in.)
I.D.(maximum)
Wheel cylinder to piston clearance - 0.15 mm (0.006 in.)
TIGHTENING TORQUE
Nm kgf·cm lbf·ft
Master cylinder to booster mounting 8 ~ 12 80 ~ 120 5.9 ~ 8.9
nut 8 ~ 12 80 ~ 120 5.9 ~ 8.9
Brake booster mounting nut 8 ~ 12 80 ~ 120 5.9 ~ 8.9
Brake booster vacuum hose fitting 7 ~ 13 70 ~ 130 5.2 ~ 9.6
to surge tank 13 ~ 17 130 ~ 170 9.6 ~ 12.5
Bleeder screw 35 ~ 55 350 ~ 550 25.8 ~ 33.2
Brake tube flare nut, brake hose 22 ~ 32 220 ~ 320 16.2 ~ 23.6
Proportioning valve mounting 35 ~ 45 350 ~ 450 25.8 ~ 33.2
Caliper guide rod bolt 69 ~ 85 690 ~ 850 50.9 ~ 62.7
Caliper pin bolt 25 ~ 30 250 ~ 300 18.4 ~ 22.1
Caliper assembly to knuckle 13 ~ 17 130 ~ 170 9.6 ~ 12.5
Brake hose to front caliper 8 ~ 10 80 ~ 100 6 ~ 7.3
Brake tube mounting nut 8 ~ 10 80 ~ 100 6 ~ 7.3
HECU mounting bolt
Wheel sensor mounting bolt
Page 11 of 72
Replace self-locking nuts with new ones after removal.
Brake System > Brake System > Brake Booster > Components and Components Location
COMPONENTS
Page 12 of 72
Brake System > Brake System > Brake Booster > Repair procedures
REMOVAL
• Be careful not to bend or damage the brake lines when removing the master cylinder.
• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
• To prevent spills, cover the hose joints with rags or shop towels.
1. Remove the air cleaner and the air duct.
2. Remove the brake fluid level switch connector.
3. After removing the brake reservoir cap, suck out the brake fluid in the reservoir using a syringe or equivalent.
4. Disconnect the brake tube from the master cylinder.
Take care not to contaminate the brake fluid.

5. Remove the master cylinder from the brake booster.
6. Remove the vacuum hose from the booster.
7. Remove the push rod from the brake pedal.

Page 13 of 72
8. Remove the booster mounting nuts.
INSTALLATION
1. Install the brake booster and tighten the mounting nut.
Tightening torque Nm (kgf·cm, lbf·ft)
Brake booster mounting nut: 8~10 (80~100, 6~7.3)
2. Apply grease to the contact points of the brake pedal and the push rod.
3. Connect the brake pedal and the clevis with a clevis pin and install the split pin to the clevis pin.
4. After installing the master cylinder, install the brake tube to the master cylinder.
Page 14 of 72
5. Connect the vacuum hose to the brake booster.
• Make sure that there are no bend, twist, or leaks in the vacuum hose.
• When installing the vacuum hose to the vacuum pipe, the vacuum pipe should be inserted to the depth
of 25~27mm (0.98~1.06 in.) as shown in the illustration.
6. Fill the brake reservoir with brake fluid, and bleed the system.
7. Check for brake fluid leaks.

8. Inspect and adjust the brake pedal.
9. After installation, apply grease to the contact points of the clevis and brake pedal sufficiently.
INSPECTION
CHECK VALVE OPERATION CHECK
Page 15 of 72
1. Remove the vacuum hose.
The check valve is press-fitted inside the vacuum hose at the position of the
marking.
2. Check the operation of the check valve by using a vacuum pump.

Vacuum pump connection Accept/Reject criteria
A negative pressure (vacuum) is created and
Connection at the brake booster side (A)
held
Connection at the intake manifold side (B) A negative pressure (vacuum) is not created
If the check valve is defective, replace it if an assembly unit together with the vacuum
hose.
Brake System > Brake System > Master Cylinder > Components and Components Location
COMPONENTS
Page 16 of 72
Brake System > Brake System > Master Cylinder > Repair procedures
REMOVAL
Page 17 of 72
1. Remove the air cleaner and the air duct.
2. Remove the brake fluid level switch connector.
3. Disconnect the brake tube from the master cylinder and install the plug.
• Be careful not to bend or damage the brake lines when removing the master
cylinder.
• Do not spill brake fluid on the vehicle; it may damage the paint.
If brake fluid does contact the paint, wash it off immediately with water.
• To prevent spills, cover the hose joints with rags or shop towels.
4. Remove master cylinder mounting nuts and then lift out the master cylinder.
INSTALLATION
1. Install the master cylinder to the brake booster.
Page 18 of 72
2. Connect the brake tubes to the master cylinder.
Check the brake tubes for bends and twists.
3. After filling the brake reservoir with brake fluid, bleed the system. (Refer to "Air bleeding in adjustment
procedure)
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. After disconnecting the mounting screws, pry the reservoir free from the master cylinder.
3. Using snap ring pliers, remove the retainer ring.
4. Remove the primary piston and the secondary piston from the master cylinder body.
Do not disassemble the primary and secondary piston assembly.
INSPECTION
1. Check the master cylinder bore for rust or scoring.
Page 19 of 72
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
1. If the cylinder bore is damaged, replace the master cylinder assembly.

2. Wash the contaminated parts in alchohol.
REASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.

3. Press against the pistons with a screwdriver and install the retainer ring.
4. Mount two grommets.

5. Install the reservoir on the cylinder.
Brake System > Brake System > Proportioning Valve > Description and Operation
DESCRIPTION
Brake System > Brake System > Proportioning Valve > Repair procedures
REMOVAL AND INSPECTION
1. Remove the proportioning valve from the master cylinder.
Page 20 of 72
2. Connect two pressure gauges; one to the input side, and one to the output side.
Be sure to bleed the system after connecting the pressure gauges.

3. With the brakes applied, measure the input pressure and the output pressure. If the measured pressures are
within the specified range, the proportioning valve is good.
4. Reconnect the brake lines in their original positions and bleed the system.
This figure shows characteristics of the proportioning valve as the pressure

increases.
INSTALLATION
1. Install the propotioning valve to the master cylinder.
Page 21 of 72
2. Tighten the flare nuts and bleed the system.
Tightening torque
Brake tube flare nut:
13~17 Nm (130~170 kgf·cm, 10~12 lbf·ft)
Proportioning valve mounting nut:
35~55 Nm (350~550 kgf·cm, 26~41 lbf·ft)
Brake System > Brake System > Brake Line > Components and Components Location
COMPONENT LOCATION
Page 22 of 72
Brake System > Brake System > Brake Line > Repair procedures
Replacement
Page 23 of 72
• Before reassembling, check that all parts are free of dust and other foreign particles.
• Replace parts with new ones whenever specified to do so.
• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
1. Replace the brake hose (A) if the hose is twisted, cracked, or if it leaks.
2. Disconnect the brake hose from the brake line (B) using a 10mm flare-nut wrench (C).
3. Remove and discard the brake hose clip (A) from the brake hose (B).
4. Remove the connector bolt (C), and disconnect the brake hose from the caliper.
5. Remove the brake hose from the knuckle.
6. Install the brake hose (A) on the knuckle with 12mm flange bolt (B) first, then connect the brake hose to the
caliper with the connector bolt (C) and new sealing washers (D).
7. Install the brake hose (A) on the upper brake hose bracket (B) with a new brake hose clip (C).
8. Connect the brake line (D) to the brake hose

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9. After installing the brake hose, bleed the brake system.
10. Perform the following checks.
A. Check the brake hose and line joint for leaks, and tighten if necessary.
B. Check the brake hoses for interference and twisting.
INSPECTION
1. Inspect the brake hoses, for damage, deterioration, leaks, interference and twisting.
2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines.
3. Check for leaks at hose and line joints or connections, and retighten if necessary.
4. Check the master cylinder for damage and leakage.
Replace the brake hose clip whenever the brake hose is

serviced.
Brake System > Brake System > Brake Pedal > Components and Components Location
COMPONENTS
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Brake System > Brake System > Brake Pedal > Repair procedures
REMOVAL
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1. Remove the stop lamp switch.
2. Remove the split pin and clevis pin.

3. Remove the brake pedal assembly mounting nut.
4. Remove the brake pedal assembly.
INSTALLATION
Be sure to install the split pin on the operating rod clevis pin. Apply the grease (NLGI
No.2)
2. Install the brake pedal assembly and tighten the flange nuts (booster mounting nuts) and bolt.
3. Install the stop lamp switch.

4. Adjust the brake pedal height and free play.
INSPECTION
1. Check the bushing for wear.
2. Check the brake pedal for distortion.
3. Check the brake pedal return spring for damage.
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4. Check the stop lamp switch.
(1) With an ohmmeter connected to the stop lamp switch terminals, check for continuity.
(2) If there is no continuity when the plunger is depressed and there is continuity when the plunger is released, the
stop lamp switch is normal.
Brake System > Brake System > Front Disc Brake > Components and Components Location
COMPONENTS
Page 28 of 72
Brake System > Brake System > Front Disc Brake > Repair procedures
REMOVAL
CALIPER ASSEMBLY
1. Remove the wheel and tire.
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2. Disconnect the brake hose.
• Do not brake fluid on the vehicle; it may damage the paint.

If brake fluid does contact the paint, wash it off immediately with
water.
• To prevent spills, plug the hose inlets with rags or shop towels.
3. Remove the cylinder mounting bolt.

4. Remove cylinder and pads from the caliper bracket.
5. Remove the caliper mounting bolts from the knuckle.

6. Remove the caliper mounting bracket.
REPLACEMENT
REMOVAL
1. Remove the lower bolt and lift the caliper assembly up and secure it with a wire or some other retaining method.
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2. Remove the pads.
Do not depress the brake pedal while disassembling the

pads.
INSPECTION
1. Check the pads for wear or oil contamination and replace, if necessary.
• The pads for the right and left wheels should be replaced at the same time. Never "drop" or intermix
brake pad sets.
• All four pads must be replaced as a complete set.
• When replacing the brake pad, check for deformation. When replacing the guide spring, use a new one
or the used one after cleaning away foreign material.
2. Check the pad for damage or deformation.

Brake pad thickness:
Standard value: 9 mm (0.354 in.)
Service limited value: 2 mm (0.0787 in.)
INSTALLATION
1. Install the pad clips.
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2. Install the pads onto each pad clip.
Position the pad with its pad wear indicator upward on the piston
side.
3. Insert the piston in the cylinder using the Special Tool (09581-11000).
4. Install the new pads. The shims are attached to each pad as illustrated.
Be careful so that the disc or pad isn't contaminated by grease.
5. Install the bolt and tighten to the specified value.

Tightening torque
Guide rod bolt: 22~32 Nm(220~320 kgf·cm, 16~24 lbf·ft)
Page 32 of 72
INSTALLATION
CALIPER ASSEMBLY
1. Be careful not to spill grease or oil on the pad and brake disc contact surface.
2. Tighten the caliper mounting bolt to the specified torque.
3. Install the brake hose.
4. Bleed the system.
DISASSEMBLY
1. Remove the piston boot.
2. Remove the piston using compressed air.
1. Do not put your fingers in front of the piston when using compressed
air.
2. Be careful not to splatter the brake fluid.
3. Remove the piston seal from the caliper by using a screwdriver.
Do not damage the piston wall surface.
INSPECTION
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1. Check the caliper for wear, damage, cracks and dust.
2. Check the piston for dust, damage, cracks and wear on the outer surface.
3. Check the sleeve and pin for damage and dust.
4. Check the pad spring and boots for damage.
5. Check the carrier for damage, dust, wear and cracks.
1. Do not use sand paper on the piston surface.

2. All rubber parts must be replaced with new
parts.
6. Inspect the disc by using a caliper and a dial gauge.

Thickness of disc mm (in.)
Standard value: 19 (0.75)
Service limit: 17 (0.67)
0.04 (0.002)
0.01 (0.0004)
1. Using a micrometer, measure the disc thickness at eight positions approximately 10mm from the outer
edge of the disc and at 45° intervals.
If you substract the minimum of measurements from the maximum, you get the difference of the disc
thickness.
2. When measuring the disc runout, fix a dial gauge approximately 5mm from the outer edge of the disc,
and rotate the disc 360°.
At this time, if you subtract the minimum of measurements from the maximum, you get the disc runout.
7. If necessary, replace the brake disc.
REASSEMBLY
1. Clean all components except the pads and shims with isopropyl alcohol.
2. Apply rubber grease on the piston seal and install the piston seal in the cylinder.
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3. Assemble the piston and piston boots according to the following procedure.
(1) Apply rubber grease to the caliper bore, the outside surface of the piston and the piston boot.
(2) Install the piston boot on the piston as illustrated.
(3) Insert the piston boot in the inner groove of the caliper and push the piston into the caliper.
4. Assemble the sliding parts according to the following procedure.

(1) Apply rubber grease to the outside surface of the sleeve and pin, pin and sleeve bore of the caliper, pin boot
and sleeve boot.
(2) Insert the boot into the groove of the caliper.
5. Install the pads.
Be careful so that the disc or pad is not contaminated by

grease.
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6. Tighten the brake hose connecting bolt.
Tightening torque Nm (kgf·cm, lbf·ft)
Sliding pin 34 ~ 44 (350~450, 26~33)
Sliding bolt 22 ~ 31 (220~320, 16~23)
Carrier mounting bolt 64 ~ 74 (650~750, 48~54)
Brake hose mounting oil bolt 25 ~ 29 (250~300, 18~22)
1. Check that the surface of the pin and bolts are not damaged before tightening.
2. Bleed the system. Depress the pedal several times and check for fluid leakage from all connecting
parts.
Brake System > Brake System > Rear Drum Brake > Components and Components Location
COMPONENTS
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Brake System > Brake System > Rear Drum Brake > Repair procedures
REMOVAL
1. Release the parking brake.
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2. After removing the wheel, remove the brake drum.
When removing the brake drum, remove the

screw.
3. Remove the adjuster spring and adjuster lever.

4. Remove the cup washer, shoe hold down spring, shoe hold down pin.
5. Move the shoe and remove the shoe adjuster.
6. Remove the lower shoe spring and upper shoe spring.

Disconnect the parking cable from the operating lever.
REPLACMENT OF WHEEL CYLINDER

1. Remove the brake shoe.
2. Disconnect the brake tube.
3. Remove the wheel cylinder assembly.
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4. Remove the dust boot.
5. Remove the piston and piston cup.
6. Remove the return spring.
7. Before assembling the wheel cylinder, inspect the following.

(1) Check the cylinder and piston for wear, damage and dust.
(2) Check the cylinder body for damage and cracks.
(3) Check the contact surface of the piston and shoes for wear.
(4) Check the piston spring for looseness.
8. Assembly is the reverse of removal.
1. Clean the cylinder and inner parts with isopropyl alcohol before
assembly.
2. Apply enough brake fluid to the piston cups and cylinder.
3. Be sure to use new piston cups and dust boots.
Be careful not to lose the steel ball in the bleeder.
INSTALLTION
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1. Apply the specified grease to the locations indicated in the illustration and to each component.
A. Shoe and backing plate contact surfaces.
B. Shoe and anchor plate contact surfaces.
Recommended grease:
2. Connect the operating lever to the parking cable.
3. Install the shoe hold-down pin.

4. Install the shoe adjuster and assemble the return spring.
5. Assemble the adjuster lever and adjuster spring.
6. Assemble the drum and pull the parking brake lever to full stroke several times.
Be sure that the inside surface of drum is not contaminated by grease or other
materials.
INSPECTION
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1. Measure the inside diameter of the brake drum.
Check the runout of the brake drum by using a dial indicator.
Inside diameter mm (in.)
Standard value: 180 (7.09)
Out-of-round (brake drum) mm (in.)

Service limit: 0.05 (0.002)
2. Measure the brake shoe lining thickness.

Lining thickness mm (in.)
Standard value: 4.8 (0.19)
3. Inspect the brake lining and drum for proper contact.
4. Inspect the wheel cylinder outside for excessive wear and damage.
5. Inspect the backing plate for wear or damage.
Brake System > Parking Brake System > Parking Brake Assembly > Components and Components
Location
COMPONENTS
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Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures
REMOVAL
1. Remove the console.
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2. Loosen the adjusting nut and detach the parking brake cable.
3. Detach the parking brake switch assembly.

4. Remove the parking brake lever assembly.
5. Remove the rear wheel.
6. Remove the brake drum.
7. Remove the rear hub assembly.
8. Remove the brake shoe.
9. Disconnect the parking brake cable from the brake shoe operating lever.
10. Remove the parking brake cable retaining ring in the rear of the backing plate.
11. Loosen the parking brake cable clamp and remove the parking brake cable assembly.
INSTALLATION
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2. Parking brake cable adjustment
(1) Depress and release the brake pedal 20 times with a force of 10 kgf.
(2) Pull the parking brake lever to full stroke more than 3 times.
(3) When pulling up the point where is at a distance of 25mm (0.98 in.) from the end of the lever with a force of
20 kgf, adjust the adjusting nut to the lever assembly so that lever is fixed to 6~7 notches.
INSPECTION
1. Check the parking brake switch operation.
2. Check the parking brake lever ratchet for wear.
3. Check the parking brake cable for wear or damage.
Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams

HYDRAULIC SYSTEM DIAGRAM
Page 44 of 72
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM (1)
CIRCUIT DIAGRAM (2)
Brake System > ABS(Anti-Lock Brake System) > Description and Operation
DESCRIPTION
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1. Enables steering around obstacles with a greater degree of certainty, even during emergency braking.
2. Enables stopping during emergency braking while keeping stability and steerability even on curves.
ABS CONTROL
1. NORMAL BRAKING
Solenoid
State Valve Passage Pump motor
valve
IN (NO) OFF OPEN Master cylinder Wheel cylinder
OFF
OUT (NC) OFF CLOSE Wheel cylinder Reservoir
Under the normal braking, voltage is not supplied to the solenoid valve, inlet valve is opened and outlet valve is
closed. When the brake is depressed, brake fluid is supplied to the wheel cylinder via solenoid valve to activate
the brake. When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve.
2. DUMP MODE
Solenoid
valve
IN (NO) ON CLOSE Master cylinder Wheel cylinder
ON
OUT (NC) ON OPEN Wheel cylinder Reservoir
Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve to
decrease the brake fluid, then voltage is supplied to each solenoid. At this time inlet valve is closed and brake
fluid is blocked from the master cylinder. Conversely outlet valve is opened and brake fluid passes through
wheel cylinder to reservoir, resulting in pressure decrease.
3. HOLD MODE
Solenoid
valve
IN (NO) ON CLOSE Master cylinder Wheel cylinder
ON
When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid valve
to keep the fluid pressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At this time inlet
and outlet valves are closed and brake fluid is kept in wheel cylinder.
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4. INCREASE MODE
Solenoid
valve
IN (NO) OFF OPEN Master cylinder Wheel cylinder
ON
If HECU determines there's no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not
supplied to each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure
increase.
EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) SYSTEM

The EBD system (Electronic Brake force Distribution) as a sub-system of the ABS system is to control the effective
adhesion utilization by the rear wheels.
It further utilizes the efficiency of highly developed ABS equipment by controlling the slip of the rear wheels in the
partial braking range.
The brake force is moved even closer to the optimum and controlled electronically, thus dispensing with the need for
the proportioning valve.
The proportioning valve, because of a mechanical device, has limitations to achieve an ideal brake force distribution
to the rear wheels.
As Well as to carry out the flexible brake force distribution proportioning to the vehicle load or weight increasing.
And in the event of malfunctioning, driver cannot notice whether it fails or not.
EBD controlled by the ABS Control Module, calculates the slip ratio of each wheel at all times and controls the
brake pressure of the rear wheels not to exceed that of the front wheels.
If the EBD fails, the EBD warning lamp (Parking brake lamp) lights up.
ADVANTAGES
- Function improvement of the base-brake system.
- Compensation for the different friction coefficients.
- Elimination of the proportioning valve.
- Failure recognition by the warning lamp.
COMPARISON BETWEEN PROPORTIONING VALVE AND EBD
FAIL SAFE
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SYSTEM WARNING LAMP
FAIL CAUSE
ABS EBD ABS EBD
None ON ON OFF OFF
Stop lamp switch failure ON ON OFF OFF
One wheel speed sensor OFF ON ON OFF
failure
Pump malfunction OFF ON ON OFF
Low voltage OFF ON ON OFF
Two or more wheel speed
sensor failure
Solenoid valve failure
HECU malfunction OFF OFF ON ON
Over voltage
Valve relay failure
Other failure
WARNING LAMP CONTROL
1. ABS warning lamp module

The active ABS warning lamp module indicates the operating condition of the ABS.
The ABS warning lamp is turned on under the following conditions.
A. During the initialization phase after ignition switch ON. (3 seconds)
B. In the event of inhibition of ABS functions by failure.
C. When the system ECU is shut down even though ignition power is applied.
D. During diagnostic mode.
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2. EBD warning lamp module
The active EBD warning lamp module indicates the operating condition of the EBD. However, in case the
parking brake switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions.
The EBD warning lamp is turned on under the following conditions.
A. During the initialization phase after ignition switch ON. (3 seconds)
B. In the event of inhibition of EBD functions by failure.
C. When the system ECU is shut down even though ignition power is applied.
D. When the parking brake switch is ON or brake fluid is low level.
Brake System > ABS(Anti-Lock Brake System) > Components and Components Location
COMPONENTS
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Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Schematic Diagrams
CIRCUIT DIAGRAM
Page 50 of 72
Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Repair procedures
REMOVAL
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1. Remove the air-cleaner and the intake hose.
2. Disconnect the double lock connector from the HECU.
3. Disconnect the brake tubes from the HECU.
• Do not spill brake fluid on the vehicle; it may damage the paint.
If brake fluid gets on the paint, wash it off immediately with water.
• Take care not to damage or deform the brake lines during removal and installation.
• To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or
equivalent material.
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4. Remove the HECU bracket mounting bolts and remove the HECU.
1. Never attempt to disassemble the HECU.

2. The HECU must be transported and stored in an upright position and with the ports
sealed.
The HECU must not be drained.
Tightening torque
HECU bracket mounting bolt:
8 ~ 10 Nm (80 ~ 100 kg cm, 6 ~ 7.3 lb ft)
INSTALLATION
1. Install the HECU, then connect the brake lines.
Tightening torque
HECU mounting bolt:
8 ~ 10 Nm (80 ~ 100 kg·cm, 6 ~ 7.3 lb·ft)
Brake tube nut:
13 ~ 17 Nm (130 ~ 170 kg·cm, 10~12 lb·ft)
2. Connect the HECU connector.

3. Bleed the brake system.
4. Start the engine, and check that the ABS indicator goes off.
5. Test-drive the vehicle, and check that the ABS indicator does not come on.
ABS OPERATION CHECK

WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK
1. Raise the vehicle and release the parking brake.
2. Disconnect the HECU harness connector’s and measure from the harness side connector.
Be sure to remove the connector’s double lock and insert the probe into the harness side (back-probe).
Inserting it into the terminal side may result in a bad connection.
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3. Rotate the wheel to be measured approximately 1/2 to 1 rotation per second, and check the output voltage using
a circuit tester or an oscilloscope.
Wheel Speed
Front left Front right Rear left Rear right
Sensor
1 19 5 22
Terminal
2 20 6 23
Output voltage :
When measuring with an oscilloscope : 130mV peak-to-peak or more
Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Specifications
INSPECTION AT HECU TERMINALS
Page 54 of 72
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Components and
Components Location
COMPONENTS
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Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures
REMOVAL
FRONT WHEEL SPEED SENSOR
1. Remove the front wheel speed sensor mounting bolt.
2. Remove the front wheel guard.

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3. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector.
REAR WHEEL SPEED SENSOR

1. Remove the rear wheel speed sensor mounting bolt.
2. Remove the luggage trim and disconnect the wire connector from the rear wheel speed sensor.
INSPECTION
1. Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.
Service standard
Front, Rear: 1,385 ± 110Ω
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2. Connect a voltmeter between the wheel speed sensor terminals and measure the voltage by turnong the wheel.
Set the voltmeter to measure AC voltage.

Service standard : AC voltage detected.
Service standard
Output voltage: Min.130mVp.p
BLEEDING OF BRAKE SYSTEM

1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
If there is any brake fluid on any painted surface, wash it off

immediately.
When pressure bleeding, do not depress the brake pedal.

Recommended fluid ......... DOT3 or DOT4
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled
clear plastic bottle.
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3. Connect the Hi-Scan (Pro) to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the Hi-Scan (Pro) screen.
You must obey the maximum operating time of the ABS motor with the Hi-Scan (Pro) to prevent the
motor pump from burning.
(1) Select hyundai vehicle diagnosis.
(2) Select vehicle name.

(3) Select Anti-Lock Brake system.
(4) Select air bleeding mode.
(5) Press ‘YES’ to operate motor pump and solenoid valve.
(6) Wait 60 sec. before operating the air bleeding.

(If not, you may damage the motor.)
5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without
bubbles. Then close the bleeder screw.
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6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.
7. Tighten the bleeder screw.

Bleed screw tightening torque:
7 ~ 13 Nm (70 ~130 kg·cm, 5 ~ 9.5 lb·ft)
Brake System > ABS(Anti-Lock Brake System) > Troubleshooting

INSPECTION FOR TROUBLE SYMPTOMS
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
NOTES WITH REGARD TO DIAGNOSIS

The phenomena listed in the following table is not abnormal.
Page 60 of 72
PHENOMENON EXPLANATION
When starting the engine, a thudding sound can sometimes be heard coming from
System check sound inside the engine compartment. This is because the system operation check is being
performed.
1. Sound of the motor inside the ABS hydraulic unit operation. (whine)
2. Sound is generated along with vibration of the brake pedal. (scraping)
ABS operation sound
3. When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release. (Thump : suspension; squeak: tires)
For road surfaces such as snow-covered and gravel roads, the braking distance for
ABS operation (Long vehicles with ABS can sometimes be longer than that for other vehicles.
braking distance) Accordingly, advise the customer to drive safely on such roads by lowering the
vehicle speed.
Pedal kick back Pedal kick back is normal operation.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom
after the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.
ABS CHECK SHEET

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HI-SCAN (PRO) CHECK

1. Turn the ignition OFF.
2. Connect the Hi-Scan (Pro) to the data link connector located underneath the lower crash pad panel.
3. Turn the ignition ON.
4. Use the Hi-Scan (Pro) to check for diagnostic trouble codes.
5. After completion of the repair or correction of the problem, erase the stored fault codes using the clear key on
the Hi-Scan (Pro).
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6. Disconnect the Hi-Scan (Pro).
INSPECTION CHART FOR TROUBLE SYMPTOMS

INSPECTION
TROUBLE SYMPTOMS
PROCEDURE NO.
Communication with Hi-Scan Communication with any system is not possible. 1
(Pro) is not possible.
Communication with ABS only is not possible. 2
When the ignition key is turned to "ON" (engine OFF), the ABS warning lamp does
3
not illuminate.
After the engine starts, the lamp remains illuminated. 4
Faulty ABS operation. Unequal braking power on both sides.
Insufficient braking power.
ABS operates under normal braking conditions.
5
ABS operates before vehicle stops under
normal braking conditions.
Large brake pedal vibration. (See Caution)
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due
to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an
abnormality
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
Communication with Hi-Scan (Pro) is not possible.
Probable cause
(Communication with all systems is not possible.)
Possible defect in the power supply system (including ground) for • Malfunction of connector.
the diagnosis line. • Malfunction of wiring harness.
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Communication with Hi-Scan (Pro) is not possible.
Probable cause
(Communication with ABS only is not possible.)
When communication with Hi-Scan (Pro) is not possible, the cause • Blown fuse.
may be probably an open circuit in the HECU power circuit or an • Malfunction of wiring harness or
open circuit in the diagnosis output circuit. connector.
• Malfunction of HECU.
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When ignition key is turned "ON" (engine OFF), the ABS warning
Probable cause
lamp does not illuminate.
When current flows in the HECU, the ABS warning lamp turns from • Blown fuse.
on to off as the initial check. • Burnt out ABS warning lamp bulb.
Therefore, if the lamp does not illuminate, the cause may be an open • Malfunction of wiring harness or
circuit in the lamp power supply circuit, a blown bulb, an open connector.
circuit in both the circuits between the ABS warning lamp and the • Malfunction of active warning lamp
HECU, and the malfunction of HECU. module.
Even after the engine is started, the ABS warning lamp remains
Probable cause
illuminated.
A possible short-circuit in the ABS warning lamp illumination • Malfunction of cluster.
circuit. • Malfunction of HECU.
• Malfunction of wiring harness.
This trouble symptom is limited to cases where communication with the Hi-Scan (Pro) is possible (HECU power
supply is normal) and DTC is normal.
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Brake operation is abnormal. Probable cause
Brake operation varies depending on • Improper installation of wheel
driving conditions and road surface speed sensor • Malfunction of wheel speed
conditions, so diagnosis can be • Incorrect sensor harness contact. sensor.
difficult. • Foreign material on wheel speed • Malfunction of rotor.
However, if a normal DTC is sensor. • Malfunction of wheel bearing.
displayed, carry out the following • Malfunction of HECU.
inspection.
Page 66 of 72
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES

Page 67 of 72
DTC Trouble Location Remarks
C1101 Battery voltage over volt : 18V or more
C1102 Battery voltage low volt : 9.5V or less
C1200 FL wheel sensor : open or short to ground
C1201 - Range/Performance : speed jump or damaged exciter
C1202 - No signal : air-gap error or wrong exciter
C1203 FR wheel sensor : open or short to ground
C1206 RL wheel sensor : open or short to ground
C1209 RR wheel sensor : open or short to ground
C1604 ECU hardware : ECU internal or valve failure
C2112 Valve relay : valve relay or fuse failure
C2402 Motor-Electrical : open or short to battery, motor relay, fuse or
motor lock fail
ACTUATOR DRIVING
NO. Description Condition Recognition Time
01 Motor Motor pump relay operation (Click sounds)
02 Front left valve Front left solenoid valve operation (Click sounds)
03 (In) Front right solenoid valve operation (Click
04 Front right valve sounds)
05 (In) Rear left solenoid valve operation (Click sounds)
06 Rear left valve (In) Rear right solenoid valve operation (Click
07 Rear right valve sounds)
KEY ON
08 (In) Front left solenoid valve operation (Click sounds) 2
ENG.
09 Front left valve Front right solenoid valve operation (Click seconds
OFF
(Out) sounds)
Front right valve Rear left solenoid valve operation (Click sounds)
(Out) Rear right solenoid valve operation (Click
Rear left valve sounds)
(Out)
Rear right valve
(Out)
CURRENT DATA
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NO. Description Recognition Unit
1 Battery Battery Voltage
Front left wheel speed
sensor
2 FL wheel speed SNSR Front right wheel speed
3 FR wheel speed SNSR sensor
km/h
4 RL wheel speed SNSR Rear left wheel speed
5 RR wheel speed SNSR sensor
Rear right wheel speed
sensor
6 ABS SRI status Warning lamp
7 Brake SW Brake switch
8 Motor pump relay Motor relay
9 Valve relay Valve relay
10 Motor pump status Motor
11 FL valve (In) Front left valve (In)
12 FR valve (In) Front right valve (In) ON/OFF
13 RL valve (In) Rear left valve (In)
14 RR valve (In) Rear right valve (In)
15 FL valve (Out) Front left valve (Out)
16 FR valve (Out) Front right valve (Out)
17 RL valve (Out) Rear left valve (Out)
18 RR valve (Out) Rear right valve (Out)
INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES

DTC No. C1200, C1203, C1206, C1209
Probable cause
Wheel speed sensor open or short to GND circuit
The HECU determines that an open or short circuit has occurred in • Malfunction of wheel speed sensor
more than one wire of a wheel speed sensor. • Malfunction of wiring harness or
connector
• Malfunction of HECU
Page 69 of 72
DTC No C1201, C1204, C1207, C1210

Probable cause
Wheel speed sensor signal error
Abnormal output signal from a wheel speed sensor other than an • Improper installation of wheel speed
open or short circuit. sensor.
• Malfunction of wheel speed sensor.
• Malfunction of rotor
• Malfunction of wheel bearing.
• Malfunction of siring harness or
connector.
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DTC No. C1202, C1205, C1208, C1211

Probable cause
(Large air gap)
No wheel speed sensor output signal. • Malfunction of wheel speed
sensor
• Improper installation of wheel
speed sensor
• Malfunction of rotor (excitor)
• Malfunction of wiring harness or
connector
• Malfunction of HECU
Page 71 of 72
DTC No. C1101, C1102 Voltage out of range.
Probable cause
(Over and under voltage)
The voltage of the HECU power supply drops lower than or rises • Malfunction of wiring harness or
higher than the specified value. If the voltage returns to the specified connector.
value, this code is no longer output. • Malfunction of HECU
• Blown ABS fuse.
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to the
standard value, the code is no longer output. Before carrying out the following inspection, check the battery level,
and refill if necessary.
DTC No. C1604 HECU Hardware.

Probable cause
HECU hardware error. (EEPROM and ECU failure)
The HECU always monitors the solenoid valve drive circuit. • Malfunction of wiring harness or
It determines that there is an open or short-circuit in the solenoid connector.
coil or in a harness even if no current flows in the solenoid or • Malfunction of HECU.
through the HECU.
DTC No. C2112

Probable cause
Valve relay error. (Including fuse failure)
When the ignition switch is turned ON, the HECU switches the • Malfunction of wiring harness or
valve relay on and off during its initial check. During this time, connector.
voltage sent to the valve relay is compared to the voltage in the • Malfunction of HECU.
valve power monitor line. If no current is detected in the valve • Malfunction of valve relay
power monitor line, the HECU determines that there is an open • Poor ground.
circuit and DTC C2112 is recorded.
Page 72 of 72
DTC No. C2402

Probable cause
Motor pump error.
When the motor power line is normal but no signal is in detected in • Malfunction of wiring harness or
the motor monitor line. connector.
• Poor ground.
Powering the motor with the Hi-Scan(Pro) will discharge the battery. Start and run the engine for a while after
testing is complete.
Page 1 of 25
ACCENT(LC) > 2005 > G 1.5 SOHC > Clutch System
Clutch System > General Information > Schematic Diagrams

CIRCUIT DIAGRAM
Clutch System > General Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and name) Illustration Use
09411-25000 Installation of the clutch disc
Clutch disc guide
Clutch System > General Information > Description and Operation

Page 2 of 25
SYSTEM CHECK
KEY LOCK SYSTEM
1. Check that the ignition key cannot be turned to "LOCK (OFF)" position, when the position of the shift lever is
not in "P" position.
2. Check that the ignition key turns to the "LOCK (OFF)" position, when the shift lever is set to the "P" position.
SHIFT LOCK SYSTEM

1. Check that under the following conditions, the shift lever cannot be movedfrom the "P" position to any other
position.
IGNITION KEY POSITION : "ON"
BRAKE PEDAL : NOT DEPRESSED
BUTTON : PRESSED
2. Check that under the following conditions, the shift lever can be moved fromthe "P" position to other position.
IGNITION KEY POSITION : "ON"
BRAKE PEDAL : DEPRESSED
BUTTON : PRESSED
Page 3 of 25
Clutch System > General Information > Components and Components Location
COMPONENTS
A. A/T and key lock control module B. A/T solenoid
C. Key lock solenoid D. "P" position switch
Clutch System > General Information > Troubleshooting

Page 4 of 25
TROUBLESHOOTING
Clutch slipping Insufficient clutch pedal free play Adjust
• Car will not respond to engine Clogged hydraulic system Correct or replace
speed during acceleration parts
• Insufficient vehicle speed Excessive wear of clutch disc facing Replace
• Lack of power during uphill Hardened clutch disc facing, or oil on surface Replace
driving Damaged pressure plate or flywheel Replace
Weak or broken pressure spring Replace
Difficult gear shifting (gear noise Excessive pedal free play Adjust
during shifting) Hydraulic system fluid leaks, air trapping or clogging Repair or replace
parts
Unusual wear or corrosion of clutch disc spline Replace
Excessive vibration (distortion) of clutch disc Replace
Clutch When clutch is not Insufficient play of clutch pedal Adjust
noisy used Excessive wear of clutch disc facing Replace
A noise is heard after Unusual wear and/or damage of release bearing Replace
clutch is disengaged
A noise is heard Insuffcient grease on the sliding surface of bearing sleeve Repair
when clutch is
disengaged Improperly installed clutch assembly or bearing Repair
A noise is heard Damaged pilot bushing Replace
when car is suddenly
rolled with clutch
partially engaged
Difficult to depress clutch pedal Insufficient lubrication of clutch pedal Repair
Insufficient lubrication of the clutch disc spline Repair
Insufficient lubrication of the clutch release lever shaft Repair
Insufficient lubrication of front bearing retainer Repair
Difficult to shift gear or cannot Excessive clutch pedal free play excessive Adjust pedal free
shift at all Clutch release cylinder faulty play
Repair release
Clutch disc out of true, runout is excessive or lining cylinder
broken Inspect clutch disc
Spline on input shaft or clutch disc dirty or burred Repair as necessary
Clutch pressure plate faulty Replace clutch cover
Clutch slips Adjust pedal free
Clutch pedal free play insufficient
play
Clogged hydraulic system
Repair or replace
parts
Clutch disc lining oily or worn out
Inspect clutch disc
Pressure plate faulty
Replace clutch cover
Release fork binding
Inspect release fork
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect clutch disc
Pressure plate faulty Replace clutch cover
Clutch diaphragm spring bent Replace clutch cover
Page 5 of 25
Worn or broken torsion spring Replace clutch disc
Engine mounts loose Repair as necessary
Clutch noisy Damaged clutch pedal bushing Replace clutch pedal
bushing
Loose part inside housing Repair as necessary
Release bearing worn or dirty Replace release
bearing
Release fork or linkage sticks Repair as necessary
Clutch System > General Information > Repair procedures

INSPECTION
TIMMING CHART
Page 6 of 25
A/T SHIFT LOCK SOLENOID

1. Remove the solenoid connector.
Page 7 of 25
2. Using an ohmmeter, measure the resistance between terminals.
Standard resistance : 12-16Ω
3. Attach the positive (+) lead from the battery to terminal #9. and the negative (-) lead to terminal #8.
4. Check that an operation noise can be heard from the solenoid.

A/T KEY INTERLOCK SOLENOID
1. Remove the solenoid connector.
2. Using an ohmmeter, measure the resistance between terminals.
Standard resistance : 12-16Ω
3. Attach the positive (+) lead from the battery to terminal #2. and the negative (-) lead to terminal #1.
4. Check that an operation noise can be heard from the solenoid.

Page 8 of 25
Clutch System > General Information > Specifications
GENERAL
SPECIFICATIONS
Item Specifications
Clutch operating method Hydraulic type
Clutch disc
Type Single dry with diaphragm.
Facing diameter (Outside x 1.5SOHC : 250 x 130
Inside) mm 1.6DOHC : 215 x 145
Clutch cover assembly
Type Diaphragm spring strap
Clutch release cylinder
I.D. mm (in.) 20.64 (0.81)
Clutch master cylinder
I.D. mm (in.) 15.57 (0.62)
I.D. : Inside Diameter
SERVICE STANDARD
Item Standard value
Clutch disc thickness
8.4 ± 0.3
[When free]
6 ~ 13 (0.24 ~ 0.52)
Clutch pedal free play
166.7 (6.6)
Clutch pedal height
145 (5.6)
Clutch pedal stroke
TIGHTENING TORQUE
Item Nm kg·cm lb·ft
Clutch pedal to pedal support member
19 ~ 28 180 ~ 280 13 ~ 20
Clutch pedal support member to master
8 ~ 10 80 ~ 100 6~7
cylinder
13 ~ 17 130 ~ 170 9 ~ 13
Clutch tube flare nut
4~6 40 ~ 60 3~4
Clutch tube bracket
15 ~ 22 150 ~ 220 11 ~ 16
Clutch release cylinder mounting bolt
25 250 18
Clutch release cylinder union bolt
15 ~ 22 150 ~ 220 11 ~ 16
Clutch cover assembly
9 ~ 14 90 ~ 140 6 ~ 10
Clutch master cylinder push rod nut
8 ~ 10 80 ~ 100 6~7
Ignition lock nut
5~7 50 ~ 70 3~5
Master cylinder reservior band
LUBRICANTS
Page 9 of 25
Items Specified lubricants Quantity
Contact surface of release bearing and fulcrum of CASMOLY L9508 As required
clutch release fork
Inner surface of clutch release bearing CASMOLY L9508 As required
Inner surface of clutch release cylinder and outer Brake fluid DOT3 or DOT4 As required
circumference of piston and cup
Inner surface of clutch disc spline CASMOLY L9508 As required
Inner surface of clutch master cylinder and outer Brake fluid DOT3 or DOT4 As required
circumference of piston assembly
Clutch master cylinder push rod, clevis pin and Wheel bearing grease SAE J310a, NLGI As required
washer No.2
Clutch pedal shaft and bushings SAE J310a, Chassis grease, NLGI-No.1 As required
Contact portion of release fork to release cylinder CASMOLY L9508 As required
push rod
Clutch System > Clutch System > Components and Components Location
CLUTCH CONTROL
COMPONENTS
Page 10 of 25
Clutch System > Clutch System > Clutch Cover And Dinode > Components and Components Location
COMPONENTS
Page 11 of 25
Clutch System > Clutch System > Clutch Cover And Dinode > Repair procedures
REMOVAL
1. Drain the clutch fluid and transaxle gear oil.
2. Remove the transaxle assembly. (Refer to the "TR" group)
3. Insert the special tool (09411-25000) in the clutch disc to prevent the disc from falling.
4. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
Page 12 of 25
5. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.
DO NOT clean the clutch disc or release bearing with cleaning solvent.
INSPECTION
CLUTCH COVER ASSEMBLY
1. Check the diaphragm spring end for wear and uneven height.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
CLUTCH DISC
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease,
and replace the clutch disc if defective.
2. Measure the thickness of the disc when free.
3. Check for the torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for
wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
CLUTCH RELEASE FORK
INSTALLATION
Page 13 of 25
1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of the
clutch release fork assembly.
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can
cause clutch slippage and judder.
2. Apply multipurpose grease into the groove of the release bearing.
Grease : CASMOLY L9508
3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork assembly.
4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make
certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
Do not apply more grease than necessary. Too much grease can cause clutch slip or judder.
6. Using the special tool (09411-25000), install the clutch disc to the flywheel. When installing the clutch disc, be
sure that the surface having the manufactures stamp is towards the pressure plate.
7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into the
flywheel.
8. Diagonally tighten the bolts 15-22 Nm (150-220 kg·cm, 11-15 lb·ft).
Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.
9. Remove the special tool.
10. Install the transaxle. (Refer to the "TR" group.)
Page 14 of 25
11. Adjust the clutch pedal free-play.
Clutch System > Clutch System > Clutch Master Cylinder > Components and Components Location
COMPONENTS
Page 15 of 25
Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures
DISASSEMBLY
1. Remove the piston stop ring.
(Refer to the components of the master cylinder)
2. Pull out the push rod and piston assembly.
Be careful not to damage the master cylinder body and piston

assembly.
INSPECTION
1. Check the inside of the cylinder body for rust, pitting or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check the clutch tube line for obstructions.
5. Measure the clutch master cylinder inside diameter with a cylinder gauge, and the piston outside diameter with a
micrometer.
REASSEMBLY
1. Apply the specified fluid to the inner surface of the cylinder body and to the outside of the piston assembly.
Specified fluid : BRAKE FLUID DOT 3 or DOT4
2. Install the piston assembly.

3. Install the piston stop ring
4. Install the push rod assembly. (Refer to the components of the clutch master cylinder.)
5. Install the clutch hose on the cylinder body.
REMOVAL
1. Drain the clutch fluid through the bleeder screw.
Page 16 of 25
2. Remove the master cylinder mounting nut.
3. Separate the clutch line.
4. Remove the clutch line clip of the transaxle side.
INSPECTION
INSTALLATION
Page 17 of 25
1. Install the clutch tube (clutch release cylinder side).
2. Install the clutch line and the clip.
3. Install the clutch master cylinder.
4. Install the push rod to the clutch pedal.

Clutch System > Clutch System > Clutch Pedal > Components and Components Location
COMPONENTS
Page 18 of 25
Clutch System > Clutch System > Clutch Pedal > Repair procedures
REMOVAL
Page 19 of 25
1. Remove the master cylinder mounting nut.
2. Remove the pedal support member mounting bolt.
3. Remove the pedal support bolt.
INSPECTION
1. Check the clutch pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or distortion.
3. Check the return spring for damage or deterioration.
4. Check the clutch pedal pad for damage or wear.
5. Measure the clutch pedal height (from the face of the pedal pad to the floorboard).
Standard value : (A) 166.7 mm (6.6 in.)

Page 20 of 25
6. If the clutch pedal height is not within the standard value range, adjust as follows :
A. Turn and adjust the bolt, then secure by tightening the lock nut.
After the adjustment, tighten the bolt until it reaches the pedal stopper and tighten the lock nut.
B. Turn the push rod to agree with the standard value and secure the push rod with the lock nut.
When adjusting the clutch pedal height, be careful not to push the push rod toward the master
cylinder.
7. After completing the adjustments, check that the clutch pedal free play (measured at the face of the pedal pad) is
within the standard value ranges.
Standard value : (B) 6~13 mm (0.24~0.52 in.)
8. If the clutch pedal free play does not meet the standard value, it may be the result of air in the hydraulic system or
a faulty clutch master cylinder. Bleed the air or disassemble and inspect the master cylinder or clutch.
IGNITION LOCK SWITCH INSPECTION

Page 21 of 25
INSTALLATION
1. Apply the multi-purpose grease and install the pedal support bolt.
Specified lubricants :
SAE J310a, Chassis grease, NLGI-No.1
2. Install the pedal supprot member mounting bolt.
3. Install the master cylinder mounting nut.
Clutch System > Clutch System > Clutch Release Cylinder > Components and Components Location
COMPONENTS
Page 22 of 25
Clutch System > Clutch System > Clutch Release Cylinder > Repair procedures
DISASSEMBLY
1. Remove the clutch hose, valve plate, spring, push rod and boot.
2. Remove any dirt from the piston bore opening of the release cylinder.
Page 23 of 25
3. Remove the piston from the release cylinder using compressed air.
1. Cover the release cylinder with rags to prevent the piston from popping out and causing
injury.
2. Apply compressed air slowly to prevent the fluid from splashing in your eyes or on your
skin.
INSPECTION
1. Check the release cylinder bore for rust and damage.
2. Measure the release cylinder bore at three locations: bottom, middle and top with a cylinder gauge.
Replace the release cylinder assembly if the bore-to-piston clearance exceeds the limit.
Limit : 0.15 mm (0.006 in.)
REASSEMBLY
1. Apply specified brake fluid to the release cylinder bore and the outer surface of the piston and piston cup.
Push the piston cup assembly into the cylinder.
Use the specified fluid : Brake fluid DOT 3 or DOT 4
2. Install the valve plate, push rod and boot.

Page 24 of 25
REMOVAL
1. Disconnect the clutch tube.
2. Remove the clutch release cylinder mounting bolt.
INSPECTION
1. Check the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder boots for damage.
INSTALLATION
1. Coat the clevis pin with the specified grease.
Specified grease : CASMOLY L9508
2. Install the clutch release cylinder, and the clutch tube.

Page 25 of 25
3. Install the clutch release cylinder mounting bolt.
Clutch System > Clutch System > Repair procedures

INSPECTION
BLEEDING
Use the specified fluid. Avoid mixing different brands of fluid. Specified fluid : SAE J1703 (DOT 3 or DOT 4).
1. Loosen the bleeder screw at the clutch release cylinder.

2. Push the clutch pedal down slowly until all air is expelled.
3. Hold the clutch pedal down until the bleeder is retightened.
4. Refill the clutch master cylinder with the specified fluid.
The rapidly-repeated operation of the clutch pedal in B-C range may cause the release cylinder's position
to be forced out from the release cylinder body during air bleeding. Repress the clutch pedal after it returns
to the "A" point completely.
Page 1 of 15
ACCENT(LC) > 2005 > G 1.5 SOHC > Driveshaft and axle
Driveshaft and axle > General Information > Special Service Tools
SPECIAL TOOLS
Tool (Number and Name) Illustration Use
09495-33000 Removal of wheel bearing inner race from
Puller hub.
09495-33100 • Removal of wheel bearing from knuckle.

Center bearing remover and (use with 09517-29000)
installer • Installation of hub to knuckle.
09517-21200 • Installation of the rear axle shaft bearing

Front axle base retainer.
• Installation of tone wheel and dust cover
to a Birfield joint.
09517-21500 • Removal of front hub from knuckle.

Front hub remover and installer (use with 09517-29000)
• Measurement of front wheel bearing pre-
load. (use with 09532-11600)
09517-29000 • Removal of front hub from knuckle.

Knuckle arm birdge (use with 09517-21500)
• Removal of wheel bearing outer race
from knuckle.
(use with 09495-33100)
09517-3A000 Removal of knuckle arm bridge.
Knuckle arm bridge holder (use with 09517-21500, 09517-29000)
09532-11600 Measurement of front wheel bearing pre-

Preload socket load.
(use with 09517-21500)
09532-31200A Installation of wheel bearing to knuckle.

Oil seal installer
09568-34000 Seperation of front lower arm and tie rod

Ball joint puller end ball joint.
Driveshaft and axle > General Information > Troubleshooting

Page 2 of 15
TROUBLESHOOTING
Vehicle pulls to one side Galling of driveshaft ball joint Replace
Wear, rattle or galling of wheel bearing Replace
Adjust or
Defective front suspension and steering
replace
Vibration Wear, damage or bending of driveshaft Replace
Driveshaft rattle and hub serration Replace
Wear, rattle or scratching of wheel bearing Replace
Shimmy Adjust or
Improper wheel balance
replace
Adjust or
replace
Excessive noise Wear, damage or bending of driveshaft Replace
Driveshaft rattle and hub serration Replace
Driveshaft rattle and side gear serration Replace
Wear, rattle or galling of wheel bearing Replace
Adjust or
Loose hub nut
replace
Adjust or
replace
Driveshaft and axle > General Information > Specifications

SPECIFICATIONS
TIGHTENING TORQUE
Page 3 of 15
Item Nm Kgf·cm lbf·ft
2200 ~
Castle nut 220 ~ 260 159 ~ 188
2600
Knuckle to strut assembly nut 75 ~ 90 750 ~ 900 54 ~ 65
Lower arm ball joint to knuckle
60 ~ 72 600 ~ 720 43 ~ 52
nut
Wheel nut 90 ~ 110 900 ~ 1100 66 ~ 81
1800 ~
Rear hub bearing flange nut 180 ~ 220 133 ~ 162
2200
Rear strut to carrier nut 75 ~ 90 750 ~ 900 55 ~ 66
1300 ~
Trailing arm to carrier nut 130 ~ 150 96 ~ 110
1500
Rear suspension arm to carrier 1300 ~
130 ~ 150 96 ~ 110
nut 1500
Stabilizer bracket nut 17 ~ 26 170 ~ 260 12 ~ 19
Stabilizer assembled nut 35 ~ 45 350 ~ 450 25 ~ 33
1000 ~
Rear suspension arm flange nut 100 ~ 120 72 ~ 87
1200
Rear suspension arm cam bolt 80 ~ 100 800 ~ 1000 58 ~ 72
Front hub to brake disk screw 10 ~ 20 100 ~ 200 7 ~ 14
Replace the self-locking nuts with new ones after removal.
LUBRICANTS
Tripod joint - Birfield joint type
driveshaft Recommended lubricant Quantity
(For 1.5L/1.6L)
Birfield joint boot grease Centoplex 278M/136K 85 ± 6 gr.
CASMOLY BJ - Joint : 40 ± 3 gr.
ROLLUBE BJ - Boot : 45 ± 3 gr.
Sunlight SW-2
Tripod joint boot grease KLK TJ 41-182 95 ± 6 gr.
CASMOLY TJ - Joint : 60 ± 3 gr.
ROLLUBE TJ - Boot : 35 ± 3 gr.
Oneluber MK
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Components and Components
Location
COMPONENTS
Page 4 of 15
COMPONENTS
Page 5 of 15
Driveshaft and axle > Driveshaft Assembly > Front Driveshaft > Repair procedures
REMOVAL
1. Loosen the wheel nuts slightly.
2. Raise the front of the vehicle, and support it with safety stands in a proper location.
3. Remove the wheel nuts and front wheel.
4. Remove the split pin, the castle nut and the washer from the front hub.
5. Drain the transmission fluid before the driveshaft is removed.
Page 6 of 15
6. Using a plastic hammer, make the driveshaft disconnected from the axle hub.
7. Push the axle hub outward and separate the driveshaft from the axle hub.
8. Insert a pry bar between the transaxle case and the tripod joint case, and pry the driveshaft from the transaxle
case.
• Be sure to apply the pry bar to the rib of the transaxle case.
• Do not insert the pry bar too deeply, as this may cause damage to the oil seal. [max. depth : 7 mm (0.28
in.)]
• For automatic transaxle equipped vehicles, insert a pry bar into the groove of the driveshaft to remove
the driveshaft from the transaxle.
• Do not pull on the driveshaft; the joints may come apart. Be sure to use the pry bar.
9. Pull out the driveshaft from the transaxle case.
• Place a plug in the hole of the transaxle case to prevent contamination

• Support the driveshaft properly.
• Replace the circlip each time the driveshaft is removed from the transaxle
case.
INSTALLATION
1. Coat gear oil on the driveshaft splines and transaxle case-sliding surface.
2. Before installing the driveshaft, set the opening side of the circlip facing downward.
3. Assemble the dust cover, the hub, the brake disc and the wheel bearing to the knuckle.
Page 7 of 15
4. Install the birfield joint into the knuckle.
5. In practice, the knuckle should be installed in the lower arm the moment the birfield joint is installed in the knuckle.
Be careful not to damage the boot.
6. Install the knuckle in the strut assembly with the tightening torque, 75~90 Nm (750~900 kgf·cm, 54~65 lbf·ft).
7. Install the lower arm in the knuckle with the tightening torque 60~72 Nm (600~720 kgf·cm, 43~52 lbf·ft).
8. After the installation, check on the driveshaft for manuever by hand.
9. After installing the washer with convex surface outward, install the castle nut and the split pin.
10. Install the wheel and tire.
INSPECTION
1. Check the boots on the driveshaft for cracks, damage, leaking grease and loose boot bands. If any damage is
found, replace the boot and boot bands.
2. Check the joints for wear and operating condition.
3. Turn the driveshaft by hand and make sure the splines and the joints are not excessively loose. If damage is found,
replace the joint.
4. Check the splines for wear and damage.

5. Make sure the driveshaft is not twisted or cracked. Replace it if necessary.
DISASSEMBLY
Page 8 of 15
• Do not disassemble the birfield joint assembly.

• The driveshaft joint uses special grease. Do not substitute with another type of grease. (see page DS-3)
• The boot band should be replaced with a new one.
1. Loosen the tripod joint boot bands and pull the tripod joint boot from the tripod joint case.
Be careful not to damage the boot.
2. Seperate the tripod joint boot from the tripod joint case.
3. Remove the snap ring and spider assembly from the driveshaft.
4. Clean the spider assembly.

5. Remove the birfield joint boot bands and pull out the birfield joint boot.
If the boot is to be reused, wrap tape around the driveshaft splines to protect the
boot.
Page 9 of 15
6. Remove the dust cover from the birfield joint assembly using the special tool(09495-33000) or a proper one.
Driveshaft and axle > Front Axle Assembly > Front Hub / Axle > Components and Components
Location
COMPONENTS
Driveshaft and axle > Front Axle Assembly > Front Hub / Axle > Repair procedures
REMOVAL
1. Raise the vehicle and remove the front wheel.
2. Remove the castle nut.
3. Remove the front caliper assembly from the knuckle and suspend it with a wire.
4. Remove the wheel speed sensor from the knuckle.
Page 10 of 15
5. Disconnect the tie rod end ball joint from the knuckle using the special tool (09568-34000).
• Be sure to tie the cord of the special tool (09568-34000) to the nearby part.
• Loosen the nut, but do not remove it.
6. Disconnect the strut assembly from the knuckle.
7. Disconnect the driveshaft from the hub.

8. Disconnect the lower arm ball joint from the knuckle using the special tool (09568-34000).
9. Remove the hub and knuckle as an assembly.
INSTALLATION
Installation is in the reverse order of removal (see page DS-13).
DISASSEMBLY
1. Remove the brake disc from the hub.
2. Remove the snap ring.
Page 11 of 15
3. Install the special tools (09517-21500, 09517-29000, 09517-3A000) as illustrated.
4. Remove the hub from the knuckle by turning the nut of the special tool (09517-21500).
5. Remove the special tools (09517-21500, 09517-29000, 09517-3A000) and the dust cover.
6. Remove the bearing inner race from the hub using the special tool (09495-33000).
7. Using the special tools (09495-33100, 09517-29000), remove the wheel bearing outer race from the knuckle.
INSPECTION
1. Check the hub for cracks and the splines for wear.
2. Check the brake disc for scoring and damage.
3. Check the knuckle for cracks.
4. Check the snap ring for crack or damage.
REASSEMBLY
1. Apply a thin coat of multi-purpose grease to the knuckle and bearing contact surface.
2. Using the special tool (09532-31200A), press the bearing into the knuckle.
• Do not press on the inner race of the wheel bearing. That will cause damage to the bearing
assembly.
• When installing a bearing assembly, always use a new one.
• Left and right bearing must be from one manufacturer.
Page 12 of 15
3. Install the dust cover.
4. Using the special tool(09495-33100), press the hub into the knuckle.
Do not press on the outer race of the wheel bearing. That will cause damage to the bearing
assembly.
5. Install the brake disc.

6. Tighten the hub to the knuckle to 220~260 Nm (2200~2600 kgf·cm, 159~188 lbf·ft) with the special tool
(09517-21500).
7. Rotate the hub several times to seat bearing.

8. Measure the hub bearing starting torque.
Hub bearing starting torque [Limit]

1.3 Nm (13 kgf·cm, 0.96 lbf·ft) or less
9. If the measuring load is 0kg, measure the hub bearing axial end play.
Page 13 of 15
10. If the hub bearing axial end play exceeds the limit while the nut is tightened to 220~260 Nm (2200~2600
kgf·cm, 159~188 lbf·ft), the bearing, hub and knuckle have not been installed correctly. Repeat the disassembly
and assembly procedure.
Hub bearing axial end play [Limit]

0.051 ~ 0.075 mm (0.0020 ~ 0.0029 in.) or less
11. Remove the special tool. (09517-21500)
Driveshaft and axle > Rear Axle Assembly > Rear Hub / Carrier > Components and Components
Location
COMPONENTS
Driveshaft and axle > Rear Axle Assembly > Rear Hub / Carrier > Repair procedures
REMOVAL
Page 14 of 15
1. Remove the wheel hub grease cap.
2. Remove the wheel bearing nut and the tongued washer.
3. Remove the screw from the brake drum.
4. Remove the brake drum.

5. Remove the wheel speed sensor from the axle carrier.
6. Remove the brake hose clip and detach the brake hose from the shock absorber.
7. Remove the rear hub unit bearing from the brake assembly.
INSTALLATION
Installation is in the reverse order of removal.
1. Install the rear hub unit bearing.
2. Assemble the tongued washer and the wheel bearing nut.
Left and right bearing must be from one manufacturer. Press inner race until it contacts the end of the
splines.
3. Hammer the wheel bearing nut for the groove in the carrier.
4. Connect the rear speed sensor.
5. Fix up the brake drum to the rear hub assembly with the screw.
6. Install the wheel hub grease cab.
Page 15 of 15
INSPECTION
1. Check the rear hub bearing for wear or damage.
2. Check the rear tone wheel for chipped teeth.
3. Check the rotating rear hub unit bearing for noise.
4. Check the hub inner surface for wear.
5. Check the carrier for cracks.
6. Check the rear hub unit bearing starting torque (it should be less than 1.8 Nm (18 kgf·cm, 1.33 lbf·ft)).
Page 1 of 64
ACCENT(LC) > 2005 > G 1.5 SOHC > Emission Control System
Emission Control System > Evaporative Emission Control System > Purge Control Solenoid Valve
(PCSV) > Troubleshooting
PURGE SOLENOID VALVE
The evaporative emission canister purge solenoid valve is a duty control type, which controls the flow of purge air
from the evaporative emission canister.
CIRCUIT DIAGRAM
USING HI-SCAN
HI-SCAN
Check item Check condition Type
display
Evaporative emission canister purge Start the engine Purge valve Activate
solenoid valve
• Actuator test
HARNESS INSPECTION PROCEDURES

Page 2 of 64
ACTUATOR INSPECTION
Refer to GROUP EC-Evaporative Emission System.
Emission Control System > Evaporative Emission Control System > Diagnosis Module - Tank Leakage
(DMTL) > Troubleshooting
DIAGNOSIS MODULE - TANK LEAKAGE (DM-TL)
The diagnosis module comprises an electromechanically driven pump together with a change-over valve and heater.
The engine management system measures the pump's electrical current consumption while pumping air into the
canister and fuel tank to check the system's leakage.
If the electrical current consumption is over the threshold value specified before in the memory, this means that there
is a tank-system leak.
CIRCUIT DIAGRAM
Page 3 of 64
TROUBLESHOOTING HINTS
1. DM-TL control signal
Page 4 of 64
2. DM-TL operating conditions.
(1) DM-TL monitoring operation starts only after all the conditions below are met.
A. Vehicle soaking over 4 hours and 30 minutes.
B. Engine coolant temperature over 2.3°C (36.14°F) when starting.
C. Ambient temperature between 1.5°C (34.7°F) and 40.5°C (104.9°F).
D. 6.4ℓ or more gasoline in the fuel tank.
E. Over 20 minutes driving after starting.
F. During Air Bag is not working.
(2) And also you can check the DM-TL operation with simulation mode of HI-SCAN.
Emission Control System > Troubleshooting > P0420

Page 5 of 64
COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
DTC DETECTING CONDITION

Item Detecting Condition Possible cause
Monitoring Strategy ● Oxygen storage capacity
● Difference of ’amplitude of downstream O2
Threshold value
sensor and ’amplitude of model signal’ : > 0.55
● Engine speed 1200-2520 rpm ● Warm-up catalytic converter
● Engine load 20-25% deteriorated.
● Catalyst temp.(model) 530-760 ● Leak in intake system.
Enable Conditions
degC(986~1400 °F) ● Faulty HO2S.
● Purge factor (high load canister) < 10 ● Faulty PCM.
● Closed loop control
Diagnostic Time ● 100 sec
Fail Safe ● None
If any codes relating to Oxygen(HO2S) sensor.MAP, injector, a P0171,P0172 are present, do all repairs
associated with them before proceeding with this troubleshooting procedure.
MONITOR DTC STATUS

1. Connect scantool to Data Link Connector(DLC).
2. Warm up the engine to normal operating temperature.
Page 6 of 64
3. Monitor the "HO2S signal" parameter on the scantool.
If the wave form of rear HO2S looks similar to that of front HO2S,catalytic converter may be broken.
Service standard
For front HO2S
-When decelerating suddeniy from 4000rpm : 200mV or less
-When engine is suddenly raced : 600~1000mV
-1500rpm : The fluctuation between 400mV or less and 600~1000mV
For Rear HO2S
-Part load(Approx. 2000rpm) : 500~1000mV
4. Is parameter displayed within specifications?
Fault is intermittent caused by poor contact in the sensor’s and/or PCM’s connector or was repaired and
PCM memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,contamination,deterioration, or
damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair" procedure.
Go to "W/Harness Inspection" procedure
TERMINAL & CONNECTOR INSPECTION

1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused
by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination,deterioration, or
damage.
3. Has a problem been found?
Repair as necessary and go to "Verification of vehicle Repair" procedure.
Go to "Signal circuit inspection" procedure.

SIGNAL CIRCUIT INSPECTION
1. Start engine and warm up to operating temperature.
Page 7 of 64
2. Measure waveform between terminal 2(up , down) of sensor harness connector and chassis ground.
3. Are the signal wave forms between front and rear HO2S about the same?
Catalytic converter faulty.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
Substitute with a known-good PCM and check for proper operation. If the problem is corrected, replace PCM
and then go to "Verification of Vehicle Repair" procedure.
VERIFICATION OF VEHICLE REPAIR

1. Monitor and record the Freeze Frame Data for the Diagnostic Trouble Code (DTC) which has been diagnosed.
2. Using a Scantool, Clear the DTCs.
3. Operate the vehicle within conditions noted in the freeze frame data or enable conditions.
4. Monitor that all rediness test have been verified as "Complete"
5. Are any DTCs present ?
Go to the applicable troubleshooting procedure.
System is performing to specification at this time.
SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 8 of 64
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring Strategy ● Rationality check
● Lambda controller : -0.06-0.06
Threshold value ● Air mass through idle control valve < 0.8kg/h
(1.7637 lb/h) ● Open in battery circuit.
● During Idle and vehicle standstill ● Open in control circuit.
● Coolant temperature > > 70 degC(158 °F) ● Short to ground in control circuit
Enable Conditions ● Altitude (model) < 2500 m ● Faulty PCSV
● Integrated purge mass > 2grams ● Faulty PCM
● Closed loop control enabled
Diagnostic Time
Fail Safe ● None
MONITOR DTC STATUS

Page 9 of 64
3. Monitor the "EVAP.PURGE VALVE" parameter on the scantool.
The data shown above is only for reference and there may be a little difference actually.
Service standard
Idle : 0 %
1000~3000 rpm : 1.5 ~ 35 %
Go to "W/Harness Inspection" procedure.

ACTUATOR TEST MODE
1. Evap. Leakage Test
Evaporative Emissions Systems (EVAP) Leak Tests can be run by the Scan Tool. The tests are automated and
provide either a pass-fail result or directions to check for DTCs.
(1) Connect scantool to Data Link Connector(DLC).

(2) Warm up the engine to normal operating temperature.
(3) Perform "07 EVAP. LEAKAGE TEST" mode
Page 10 of 64
(4) Is DTC P0441 set again?
PCM memory was not cleared. Thoroughly check connectors for looseness, poor connection,bending,
corrosion, contamination, deterioration, or damage. Repair or replace as necessary and go to "Verification
vehicle Repair" procedure

damage.
Go to "Power Circuit inspection" procedure.

POWER CIRCUIT INSPECTION
1. Ignition "OFF"
2. Disconnect PCSV sensor connector.
3. Ignition "ON" & Engine "OFF"
4. Measure voltage between terminal 1 of PCSV harness connector and chassis ground.
5. Is measure voltage within Specification?
Go to "Control circuit insepction" procedure.
Open circuit or short circuit to chassis ground between PCSV harness connector and battery power circuit.
In case the voltage at terminal 1 of PCSV is 0 V when PCSV is disconnected.

Possible cause:Open or short circuit in battery power line after fuse(15A INJ)
CONTROL CIRCUIT INSPECTION

Page 11 of 64
1. Check for open in harness
(1) Ignition "OFF"
(2) Disconnect PCSV sensor connector.
(3) Ignition "ON" & Engine "OFF"
(4) Measure voltage between terminal 2 of PCSV harness connector and chassis ground.
(5) Is measure voltage within Specification?
Go to "Component Inspection" procedure.
Open circuit between PCSV harness connector and PCM harness connector.
Short circuit to chassis ground between PCSV harness connector and PCM harness connector.
In case the measured voltage is 0V when checking control line

Possible cause:If the measured voltage indicates 0V,the problem is that control line is open, so
check the open circuit between terminal 46 of PCM and terminal 2 of PCSV
COMPONENT INSPECTION
1. Check Operation of PCSV
(1) Ignition "OFF"
(2) Disconnect valve connector and Remove Purge Control Valve.
(3) Check that no air flows through valve.
(4) Apply 12V and a ground to 1 and 2 terminals of the Purge Control Valve.(To sensor side)
(5) Verify that air flows through valve
Page 12 of 64
(6) Does Purge Control Valve work properly ?
Substitute with a known-good PCM and check for proper operation. If the problem is corrected, replace
PCM and then go to "Verification of Vehicle Repair" procedure.
Substitute with a known-good PCSV and check for proper operation. If the problem is corrected, replace
PCSV and then go to "Verification of Vehicle Repair" procedure.
The purpose of measuring injector resistance is to find if the open circuit is in the component.So,check
the continuity between signal line and ground line.

SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 13 of 64
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring ● Pump motor current at monitor mode
Strategy (rough leak)
● Increment of pump motor current < 1.08-
Threshold value
2.34 mA
● Fuel filler cap loose or missing.
● PCM at power down ● Fuel filler cap o-ring missing or
● Last soak time (model) > 5 hrs damaged.
Case1 ● Duration of driving > 20 min ● Faulty or damaged fuel filler pipe.
Enable ● Fuel tank level 15-85 % ● Leaking, disconnected or plugged
Conditions ● Ambient temp. (model) 1.5-40.5 fuel vapor lines.
degC(34.7~104.9 °F) ● Fuel in lines due to faulty
● Altitude (model) < 2500 m rollover(RV),on-board vapor recovery
● Battery voltage 11.5-14.5 V valve(ORVR valve).
Diagnostic ● Improperly installed purge solenoid
Time (PSV).
● PSV stuck open or closed.
Monitoring ● Pump motor current at monitor mode ● Leaking canister or catch tank
Strategy (small leak) ● Faulty leak detection module
● Elapsed time to increase 0.5mA < 19-28 solenoid valve.
Threshold value
sec ● Faulty leak detection module.
Case1 ● Faulty PCM
Enable
● Refueling > 5 L
Conditions
Diagnostic
Time
MONITOR DTC STATUS

Page 14 of 64

PCM memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending,
vehicle Repair" procedure.

damage.
Page 15 of 64
1. Check Fuel Filler Cap
(1) Warm-up engine to normal operating temperature.
(2) Check fuel filler cap, o-ring seal for being tightly installed, and in good condition.
(3) Verify cap releases vacuum at specified values (approximately 2psi pressure and approximately 1.5 inches hg
vacuum)
(4) Are cap, o-ring and release pressures OK?
Go to "Check Fuel Filler Pipe" as below
Substitute with a known-good Fuel Filler Cap and check for proper operation. If the problem is corrected,
replace Fuel Filler Cap and then go to "Verification of Vehicle Repair" procedure.
2. Check Fuel Filler Pipe
(1) Check fuel filler pipe for cracks, damage and o-ring seat for deformation.
(2) Is fuel filler pipe okay?
Go to "Thorounghly check all Fuel vapor hoses clamps " as below

3. Thorounghly check all Fuel vapor hoses clamps between;
Canister and rollover valve.
Canister and ORVR valves.
Canister and catcher tank.
Canister and DMTL.
Canister and PSV.
PSV and intake manifold(At this point, verify arrow on PSV is pointing towards intake manifold. If it is not,
reverse installation).
(1) With system sealed and pressurized, check for leaks with a R134a leak detector.
(2) Are vapor hoses and clamps okay?
Go to "Check PSV" as below
Replace all cracked/damaged hoses loose clamps go to "Verification Vehicle Repair" procedure.
4. Check PSV
(1) Turn ignition OFF and disconnect hose leading from PSV to intake manifold at PSV. Draw a vacuum at
nipple and verify PSV hold vacuum. Turn ignition to ON and jumper a wire to chassis ground at PSV control
terminal 1 (should hear a faint click from PSV). Vacuum chould bleed off. Repeat this procedure 4 or 5 times
to ensure PSV reliadility.
(2) Is PSV working properly?
Go to "Check DM-TL" as below
Substitute with a known-good PCV and check for proper operation. If the problem is corrected, replace
PCV and then go to "Verification of Vehicle Repair" procedure.
Page 16 of 64
5. Check DM-TL
(1) Temporarily install a new DM-TL and check for proper operation.
(2) Is problem still remained ?
Substitute with a known-good DM-TL and check for proper operation. If the problem is corrected,
replace DM-TL and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 17 of 64
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring
● Circuit continuity check, low ● Open in battery circuit
Strategy
● Open in control circuit
Threshold value ● Short circuit to ground or disconnected
● Short to ground in control
Enable Conditions ● Open circuit circuit
Diagnostic Time ● Continous ● Faulty PCSV
● Faulty PCM
Fail Safe ● None
MONITOR DTC STATUS

Page 18 of 64
Service standard
Idle : 0 %
1000~3000 rpm : 1.5 ~ 35 %
PCM memory was not cleared.Thoroughly check connectors for looseness, poor connection, bending,
corrosion,contamination,deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.

damage.

1. Ignition "OFF"
2. Disconnect PCSV sensor connector.
Page 19 of 64
4. Measure voltage between terminal 1 of PCSV harness connector and chassis ground.
Open circuit or short circuit to chassis ground between PCSV harness connector and battery power circuit.

Possible cause:Open or short circuit in battery power line after fuse(15A INJ)

(1) Ignition "OFF"
Open circuit between PCSV harness connector and PCM harness connector.
In case the measured voltage is 0V when checking control line

Possible cause:If the measured voltage indicates 0V,the problem is that control line is open,so check
the open circuit between terminal 46 of PCM and terminal 2 of PCSV
Page 20 of 64
1. Check PCSV
(1) Measure resistance between terminal 1 and 2 of sensor connector(To sensor side)
(2) Is measure resistance within Specification?

SCHEMATIC DIAGRAM
Page 21 of 64

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 22 of 64
Monitoring
● Circuit continuity check, high
Strategy
Threshold value ● Short circuit to battery ● Short to battery in control
circuit
Enable
● Short circuit ● Faulty PCSV
Conditions
● Faulty PCM
Diagnostic Time ● Continous
Fail Safe ● None
MONITOR DTC STATUS

Service standard
Idle : 0 %
1000~3000 rpm : 1.5 ~ 35 %

damage.
Page 23 of 64

1. Check for short to power in harness
(1) Ignition "OFF"

Possible cause : Short circuit in battery power line after fuse(15A INJ)
Page 24 of 64
1. Check PCSV

SCHEMATIC DIAGRAM
Page 25 of 64

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring ● Circuit continuity check (Pump
Strategy motor)
Threshold value ● Disconnected
● Open in control circuit.
Enable ● Faulty DMTL.
● open circuit
Conditions ● Faulty PCM.
Diagnostic Time ● Continuous
Fail Safe
MONITOR DTC STATUS

Page 26 of 64


damage.
Go to "Power circuit inspection" procedure.

1. Ignition "OFF"
2. Disconnect DM-TL connector.
Page 27 of 64
4. Measure voltage between terminal 4 of DM-TL harness connector and chassis ground.
Short circuit to chassis ground between DM-TL harness connector and control relay.
Open circuit between DM-TL harness connector and control relay.
1. In case,when DM-TL connector is disconnected, the voltage of DM-TL terminal 4 is

0V.
Possible cause: Open or short circuit in battery power line after fuse (10A ECU
#1).
2. ECM also sets P0444 and P0562 if it detects the open circuit in DM-TL power line.

(1) Ignition "OFF"
(2) Disconnect DM-TL connector.
(4) Measure voltage between terminal 1 of DM-TL harness connector and chassis ground.
Page 28 of 64
Short circuit to chassis ground between DM-TL harness connector and PCM harness connector
Open circuit between DM-TL harness connector and PCM harness connector
In case,when the DM-TL connector is disconnected,the voltage of DM-TL terminal 1 is 0

V.
Possible cause: Open or short between terminal 30 of PCM and terminal 1 of DM-TL.
1. Check for short between Pump Control and battery.
(1) Ignition "OFF"
(2) Disconnect Fuel sender connector.
(3) Measure resistance between terminal 1 and 4 of Fuel sender harness connector.(To sender side)
Substitute with a known-good Pump motor and check for proper operation. If the problem is corrected,
replace Pump motor and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 29 of 64

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring
● Circuit continuity check (Pump motor)
Strategy ● Open in control circuit
Threshold value ● Shorted to GND ● Short to ground in control
circuit.
Enable Conditions ● Open circuit
● Faulty DMTL.
Diagnostic Time ● Continuous ● Faulty PCM
Fail Safe
MONITOR DTC STATUS

Page 30 of 64


damage.

Page 31 of 64
1. Check for short to ground in harness
(1) Ignition "OFF"
(2) Disconnect DM-TL connector and PCM connector.
(4) Measure resistance between terminal 1 of DM-TL harness connector and chassis ground..
Go to "Check for short between Pump Control and Solenoid Control harness " as below.
Short circuit to chassis ground between DM-TL harness connector and PCM harness connector.
2. Check for short between Pump Control and Solenoid Control harness
(1) Ignition "OFF"
(2) Disconnect DM-TL connector and PCM connector.
(4) Measure resistance between terminal 1 and 2 of DM-TL harness connector.
Shorted circuit between Pump Control circuit and Solenoid Control circuit.
Page 32 of 64
1. Check for short between Pump Control and chassis ground.
(1) Ignition "OFF"
(3) Measure resistance between terminal 1 of DM-TL harness connector and chassis ground.(To DM-TL side)

SCHEMATIC DIAGRAM
Page 33 of 64

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring
● Circuit continuity check (Pump motor)
Strategy
● Short to battery in control
Threshold value ● Shorted to battery voltage
circuit
Enable Conditions ● Shorted circuit ● Faulty DMTL.
● Faulty PCM
Fail Safe
MONITOR DTC STATUS

Page 34 of 64


damage.

Page 35 of 64
1. Check for short between battery and Pump control harness
(1) Ignition "OFF"
Check for short to battery in Pump control harness.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure

V.
Possible cause: Short circuit in battery power line after fuse. (10A ECU #1)
1. Check for short between Pump Control and battery.
(1) Ignition "OFF"
Page 36 of 64

SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 37 of 64
Monitoring
● DM-TL : pump motor current
Strategy
● Current at valve check > ref. current-2
Threshold value ● Leakage on EVAP. SYSTEM
mA
● Faulty DMTL.
Enable Conditions ● Faulty PCM
Diagnostic Time ● 1.5-2.5 s
Fail Safe
MONITOR DTC STATUS



damage.
Page 38 of 64
Go to "Power circuit insepction" procedure.

1. Ignition "OFF"
Check for open or short circuit between Main relay and terminal 3 of DM-TL
Especially check "10A ECU" fuse is blown or not installed Repair as necessary and go to "Verification Vehicle
Repair" procedure.
1. Ignition "OFF"
Check for Open or short in Solenoid Control harness.

Page 39 of 64
1. Check Solenoid
(1) Ignition "OFF"
(3) Measure resistance between terminal 2 and 4 of DM-TL harness connector.(To sender side)
Go to "Check Pump" as below.
2. Check Pump
(1) Ignition "OFF"

Page 40 of 64
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 41 of 64
Monitoring
Strategy
● Current at reference mode phase < 12
Ma
● Faulty DMTL.
Fail Safe
MONITOR DTC STATUS



damage.
Page 42 of 64

1. Ignition "OFF"
Repair" procedure.
1. Ignition "OFF"

Page 43 of 64
1. Check Solenoid
(1) Ignition "OFF"
2. Check Pump
(1) Ignition "OFF"

Page 44 of 64
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 45 of 64
Monitoring
Strategy
● Current at reference mode phase > 40
mA
● Faulty DMTL.
Fail Safe
MONITOR DTC STATUS



damage.
Page 46 of 64

1. Ignition "OFF"
Repair" procedure.
1. Ignition "OFF"

Page 47 of 64
1. Check Solenoid
(1) Ignition "OFF"
replace DM-TL and then go to "Verification of Vehicle Repair" procedure..
2. Check Pump
(1) Ignition "OFF"

Page 48 of 64
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 49 of 64
Monitoring Strategy ● DM-TL : pump motor current
● Number of not ended leak detection due to
current change > 8
● Faulty DMTL
Enable Conditions
● Faulty PCM
Diagnostic Time
Fail Safe
MONITOR DTC STATUS



damage.
Page 50 of 64

1. Ignition "OFF"
Repair" procedure.
1. Ignition "OFF"

Page 51 of 64
1. Check Solenoid
(1) Ignition "OFF"
Substitute with a known-good DM-TL and check for proper operation. If the problem is
corrected,replace DM-TL and then go to "Verification of Vehicle Repair" procedure .
2. Check Pump
(1) Ignition "OFF"

Page 52 of 64
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 53 of 64
Monitoring ● Circuit continuity check (Change-over
Strategy valve)
Enable ● Faulty DMTL
● Open circuit
Conditions ● Faulty PCM
Fail Safe
MONITOR DTC STATUS



damage.
Page 54 of 64

1. Ignition "OFF"

0V.
#1).
2. PCM also sets P0444 and P0562 if it detects the open circuit in DM-TL power line.

Page 55 of 64
(1) Ignition "OFF"
Short circuit to chassis ground between DM-TL harness connector and ECM harness connector

V.
1. Check for short between Solenoid Control and battery
(1) Ignition "OFF"
Page 56 of 64
Substitute with a known-good PCM and check for proper operation. If the problem is corrected replace

SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 57 of 64
GENERAL DESCTIPTION
DTC DESCRIPTION

Strategy valve)
Enable ● Faulty DMTL
● Open circuit
Conditions ● Faulty PCM
Fail Safe
MONITOR DTC STATUS



Page 58 of 64
damage.

1. Ignition "OFF"

0V.
#1).
2. PCM also sets P0444 and P0562 if it detects the open circuit in DM-TL power line.

Page 59 of 64
(1) Ignition "OFF"
Short circuit to chassis ground between DM-TL harness connector and ECM harness connector

V.
1. Check for short between Solenoid Control and battery
(1) Ignition "OFF"
Page 60 of 64
Substitute with a known-good PCM and check for proper operation. If the problem is corrected replace

SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 61 of 64
GENERAL DESCTIPTION
DTC DESCRIPTION

Strategy valve)
Threshold value ● Shorted to battery voltage ● Short to battery in control circuit
● Faulty DMTL
Enable Conditions ● Shorted circuit
● Faulty PCM
Fail Safe
MONITOR DTC STATUS



Page 62 of 64
damage.

1. Check for short between battery and Solenoid control harness
(1) Ignition "OFF"
Check for short to battery in Pump control harness.


V.
Possible cause: Short circuit in battery power line after fuse. (10A ECU #1)
Page 63 of 64
1. Check for short between Solenoid Control and battery.
(1) Ignition "OFF"
Substitute with a known-good PCM and check for proper operation. If the problem is corrected, eplace

SCHEMATIC DIAGRAM
Page 64 of 64
Page 1 of 100
ACCENT(LC) > 2005 > G 1.5 SOHC > Engine Electrical System
Engine Electrical System > General Information > General Information

THE MICRO 570 ANALYZER
Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when
working with batteries.
KEYPAD
BATTERY TEST PROCEDURE

1. Connect the tester to the battery.
A. Red clamp to battery positive (+) terminal.
B. Black clamp to battery negative (-) terminal.
Connect clamps securely. If "CHECK CONNECTION" message is displyed on the screen, reconnect
clamps securely.
Page 2 of 100
2. The tester will ask if the battery is connected "IN A VEHICLE" or "OUT OF A VEHICLE".
Make your selection by pressing the arrow buttons; then press ENTER.
3. Choose eigher CCA or CCP and press the ENTER button.
- CCA : Cold cranking amps, is an SAE specification for cranking batteried at 0°F (-18°C).
- CCP : Cold cranking amps, is an SAE specification for korean manufacturer's for cranking batteries at
0°F (-18°C)
4. Set the CCA value displyed on the screen to the CCA value marked on the battery label by pressing up and
down buttons and press ENTER.
The battery ratings(CCA) displyed on the tester must be identical to the ratings marked on battery label.
Page 3 of 100
5. The tester (Micro570) displays battery test results including voltage and battery ratings.
A relevant action must be given according to the test results by referring to the battery test results as shown in the
table below.
6. To conduct starter test, continuously, press ENTER.

BATTERY TEST RESULTS
RESULT ON PRINTER REMEDY
Good battery No action is required
Battery is in a good state
Good recharge
Recharge the battery and use
Battery is not charged properly
Charge & Retest → Charge and test the battery again (Failure to charge the battery fully may
read incorrect measurement value)
→ Replace battery and recheck the charging system. (Improper connection
between battery and vehicle cables may cause "REPLACE BATTERY",
Replace battery
retest the battery after removing cables and connecting the tester to the
battery terminal directly prior to replacing the battery)
→ Charge and retest the battery. And than, test results may cause
Bad cell-replace
"REPLACE BATTERY", replace battery and recheck the charging system
Whenever filing a claim for battery, the print out of the battery test results must be attached.
STARTER TEST PROCEDURE
1. After the battery test, press ENTER immediately for the starter test.
Page 4 of 100
2. After pressing ENTER key, start the engine.
3. Cranking voltage and starter test results will be displayed on the screen.
Take a relevant action according to the test results by referring to the starter test results as given below.
4. To continue charging system test, press ENTER.

STARTER TEST RESULTS
Cranking voltage normal System shows a normal starter draw
Cranking voltage is lower than normal level
Cranking voltage low
→ Check starter
The state of battery charge is too low to test
Charge battery
→ Charge the battery and retest
→ Replace battery
If the vehicle is not started though the battery condition of "Good and fully
charged" is displayed.
Replace battery
→ Check wiring for open circuit, battery cable connection, starter and repair
or replace as necessary.
→ If the engine does crank, check fuel system.
When testing the vehicle with old diesel engines, the test result will not be favorable if the glow plug is not
heated. Conduct the test after warming up the engine for 5 minutes.
CHARGING SYSTEM TEST PROCEDURE
Page 5 of 100
1. Press ENTER to begin charging system test.
2. If ENTER button is pressed, the tester displays the actual voltage of alternator.
Press ENTER to test the charging system.
3. Turn off all electrical load and rev engine for 5 seconds with pressing the accelerator pedal.
4. Press ENTER.
5. The MICRO 570 analyzer charging system output at idle for comparision to other readings.
Page 6 of 100
6. Take a relevant action according to the test results by referring to the table below after shutting off the engine and
disconnect the tester clamps from the battery.
CHARGING SYSTEM TEST RESULTS

Charging system normal/Diode
Charging system is normal
ripple normal
Alternator does not supply charging current to battery
No charging voltage → Check belts, connection between alternator and battery
Replace belts or cable or alternator as necessary
Alternator does not supply charging current to battery and electrical load to
Low charging voltage system fully
→ Check belts and alternator and replace as necessary
The voltage from alternator to battery is higher than normal limit during voltage
regulating.
High charging voltage
→ Check connection and ground and replace regulator as necessary
→ Check electrolyte level in the battery
One or more diodes in the alternator is not functioning properly
Excess ripple detected
→ Check alternator mounting and belts and replace as necessary
Engine Electrical System > General Information > Troubleshooting

TROUBLESHOOTING
IGNITION SYSTEM
Symptom Suspect Area Remedy (See Page)
Engine will not start or is hard to Ignition lock switch See page EE-14
start (Cranks OK) Ignition coil See page EE-13
Spark plugs See page EE-12
Ignition wiring disconnected or broken Repair
Spark plug cable See page EE-12
Rough idle or stalls Ignition wiring Inspect
Ignition coil See page EE-13
Spark plug cable See page EE-12
Engine hesitates/poor Spark plugs and spark plug cable See page EE-12
acceleration Ignition wiring Inspect
Poor mileage Spark plugs and spark plugs cable See page EE-12
CHARGING SYSTEM
Page 7 of 100
Charging warning indicator Fuse blown Check fuses
does not light with ignition Light burned out Replace light
switch "ON" and engine off Wiring connection loose Tighten loose connections
Electronic voltage regulator See page EE-19
Charging warning indicator Drive belt loose or worn See page EE-27
does not go out with engine Battery cables loose, corroded or worn Repair
running (Battery requires Fuse blown Check fuses
frequent recharging) Fusible link blown Replace fusible link
Electronic voltage regulator or generator See page EE-19
Wiring Repair wiring
Engine hesitates/poor Drive belt loose or worn See page EE-27
acceleration Wiring connection loose or open circuit Tighten loose connection or repair
Overcharge wiring
Fusible link blown Replace fusible link
Poor grounding Repair
Electronic voltage regulator or generator See page EE-19
Worn battery Replace battery
Electronic voltage regulator See page EE-19
Voltage sensing wire Repair wire
STARTING SYSTEM
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Transaxle range switch (Vehicle with See page TR group-automatic
automatic transaxle only) transaxle
Fusible link blown
Starter motor Replace fusible link
Ignition switch See page EE-37
See page EE-14
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Starter motor See page EE-37
Starter keeps running Starter motor See page EE-37
Ignition switch See page EE-14
Starter spins but engine will Short in wiring Repair wiring
not crank Pinion gear teeth broken or starter motor See page EE-37
Ring gear teeth broken See page EM group-fly wheel
Engine Electrical System > General Information > Specifications

SPECIFICATION
IGNITION SYSTEM
Page 8 of 100
Ignition coil
Type Mold coil type
Primary resistance 0.87 ± 10% (Ω)
Secondary 13.0 ± 15% (kΩ)
resistance
Spark plugs
NGK BKR5ES-11
CHAMPION RC10TC4
Gap 1.0 ~ 1.1 mm
STARTING SYSTEM
Starter
Type
Direct drive type
Rated voltage
12V, 0.9KW
No. of pinion teeth
8
No-load
characteristics
11.5V
Voltage
60A, Max.
Amperage
5,500 rpm, Min.
Speed
Commutator diameter
29.4 mm (1.157 in.)
Standard
28.4 mm (1.118 in.)
Limit
Undercut depth
0.5 mm (0.02 in.)
Standard
0.2 mm (0.008 in.)
Limit
CHARGING SYSTEM
Alternator
Type Battery voltage sensing
Rated voltage 13.5V, 90A
Speed in use 1000 ~ 18,000 rpm
Voltage regulator Electronic built-in type
Regulator setting voltage 14.55 ± 0.2V
Temperature compensation -10 ± 3 mV/°C
Battery
Type
Cold cranking amperage [at - MF55AH
18°C (0°F)] 500A
Reserve capacity 85min
Specific gravity [at 25°C 1,280 ± 0.01
(77°F)]
Page 9 of 100
- COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a
terminal voltage of 7.2 or greater at a specified temperature.
- REVERSE CAPACITY RATING is amount of time a battery can deliver 25A and maintain a minimum
terminal voltage of 10.5 at 26.7°C(80°F)
TIGHTENING TORQUE
Items Nm kg·cm lb·ft
Generator terminal
(B+) 5~7 50 ~ 70 3.6 ~ 5.1
Starter motor terminal 10 ~ 12 100 ~ 120 7.3 ~ 8.8
(B+) 4~6 40 ~ 60 2.9 ~ 4.3
Battery terminal 20 ~ 30 200 ~ 300 15 ~ 22
Spark plug
Engine Electrical System > Ignition System > Ignition Coil > Troubleshooting
IGNITION COIL
When the ignition power transistor is turned ON by a signal from the ECM, the ECM sends a signal to the ignition
coil, then the primary current is shut off and a high voltage is induced in the secondary coil.
CIRCUIT DIAGRAM
Page 10 of 100
Engine Electrical System > Ignition System > Description and Operation
DESCRIPTION
Engine Electrical System > Ignition System > Repair procedures

Page 11 of 100
ON-VEHICLE INSPECTION
INSPECT SPARK TEST
1. Remove the spark plug cable.
2. Using a spark plug socket, remove the spark plug.
3. Remove the ignition coil.
4. Install the spark plugs to each spark plug cable.
5. Ground the spark plugs.
6. Check is spark occurs while engine is being cranked.
To prevent gasoline from being injected from injectors during this test, crank the engine for no more then 5~10
seconds at time.
7. Using a spark plug socket, install the spark plugs.

8. Install the spark plug cable and ignition coil.
INSPECT SPARK PLUG AND SPARK PLUG CABLE
Page 12 of 100
1. Remove the spark plug cable(A).
When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it may be
damaged.
2. Using a spark plug socket, remove the spark plug(B).
Be careful that no contaminats enter through the spark plug

holes.
3. Inspect the electrodes(A) and ceramic insulator(B).
INSPECTION FO ELECTRODES
CONDITION DARK DEPOSITS WITHE DEPOSITS
- Fuel mixture too - Fuel mixture too
rich lean
- Low air intake - Advanced ignition
DESCRIPTION
timing
- Insufficient plug
tightening
Page 13 of 100
4. Check the electrode gap(A).
Standard (New)
1.0~1.1 mm (0.039~0.043 in.)
5. Carefully remove the spark plug cable by pulling on the rubber boots(A).
Check the condition of the spark plug cable terminals(B), if any terminal is corroded, clean it, and if it broken or
distorted, replace the spark plug cable.
6. Connect the ohmmeter probes and measure resistance.
RESISTANCE : 5.6KΩ/m ± 20%
7. Resistance should not be higher than 10K per meter of cable.

If resistance is higher, replace the cable.
INSPECT IGNITION COIL
1. Measure the primary coil resistance between terminals 1 and 2.
Standard value : 0.87Ω ± 10%

Page 14 of 100
2. Measure the secondary coil resistance between the high-voltage terminal for the No.1 and No.4 cylinders, and
between the high-voltage terminals for the No.2 and No.3 cylinders.
Standard value : 13.0kΩ ± 15%
Be sure, when measuring the resistnace of the secondary coil, to disconnect the connector of the ignition
coil.
INSPECT IGNITION SWITCH

1. Remove the connector located under the steering column.
If there is no continuity, replace the ignition switch.
REPLACEMENT
IGNITION COIL
Page 15 of 100
1. Disconnect the spark plug cable and connector.
2. Remove the ignition coil(A).
CRANKSHAFT POSITION SENSOR

1. Disconnect the crankshaft position sensor connector.
2. Remove the crankshaft position sensor(A).
CAMSHAFT POSITION SENSOR
1. Disconnect the camshaft position sensor connector.
2. Remove the camshaft position sensor(B).
Engine Electrical System > Charging System > Schematic Diagrams

CIRCUIT DIAGRAM FOR CHARGING SYSTEM
Page 16 of 100
Engine Electrical System > Charging System > Alternator > Components and Components Location
COMPONENTS
Page 17 of 100
Engine Electrical System > Charging System > Alternator > Repair procedures
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
Page 18 of 100
2. Deisconnect the generator connector(A) and "B" terminal cable(B) from the generator(C).
3. Remove the adjusting bolt(A) and mounting bolt(B), then remove the generator belt(C).
4. Pull out the through bolt(C), then remove the generator(D).

6. Adjust the generator belt tension after installation (See page EE-27).
DISASSEMBLY
1. Remove the generator cover(A) using a screw driver(B).
2. Loosen the mounting bolts(A) and disconnect the brush holder assembly(B).
Page 19 of 100
3. Remove the slip ring guide(A).
4. Remove the nut, pully and spacer.
5. Loosen the 4 through bolts(A).
6. Disconnect the rotor(A), front cover(B), and rear cover(C).
7. Reassembly is the reverse of disassembly.
INSPECTION
INSPECT ROTOR
Page 20 of 100
1. Check that there is continuity between the slip rings(A).
2. Check that there is no continuity between the slip rings and the rotor or rotor shaft.
3. If the rotor fails either continuity check, replace the generator.
INSPECT STATOR
1. Check that there is continuity between each pair of leads(A).
2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the generator.
ALTERNATOR BELT INSPECTION AND ADJUSTMENT
When using a new belt, first adjust the deflection or tension to the values for the new belt, then readjust the
deflection or tension to the values for the used belt after running engine for five minutes.
Deflection method :
Apply a force of 98N (10 kgf, 22 lbf), and measure the deflection between the alternator and crankshaft pulley.
Deflection
Used Belt : 8.5 ~ 11.5 mm (0.33 ~ 0345 in)
New Belt : 5.5 ~ 8.0 mm (0.22 ~ 0361 in)
If the belt is worn or damaged, replace it.
Belt tension gauge method :

Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions.
Page 21 of 100
Tension
Used Belt : 340~490 N (35~50 kgf, 77~110 lbf)
New Belt : 690~880 N (70~90 kgf, 150~200 lbf)
If the belt is worn or damaged, replace it.
If adjustment is necessary :
1. Loosen the adjusting bolt(A) and the lock bolt(B).
2. Move the alternator to obtain the proper belt tension, then retighten the nuts.
3. Recheck the deflection or tension of the belt.
For the power steering pump belt and A/C compressor belt adjustments, refer to section 17 and section
22.
Engine Electrical System > Charging System > Battery > Description and Operation
DESCRIPTION
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell
caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.
Page 22 of 100
Engine Electrical System > Charging System > Battery > Repair procedures
INSPECTION
BATTERY DIAGNOSTIC TEST (1)
1. CHECKING FLOW
2. CHECKING SHEET
Responsibility
Inspection Items & contents Judgment criteria Remarks
User Manufacturera
1. Acid Leakage 1. Damage in the case or cover
* Type of acid leakage ○
due to outside impact.
- Leakage on the fusion part for
joining the case and cover. 2. Acid leakage on the molding
- Leakage on the terminal part part of the case or cover. ○
- Leakage on the other parts (weld line or gate hole)
* Clean the wet part or wash it, 3. Damage on the terminal or
then dry it before checking with ○
cracks in the cover.
naked eyes.
* Determine a part where leakage 4. Acid leakage due to the tipped
○
might have occurred battery or slant storage.
; check it by tipping the battery, if
the leakage takes place again. 5. Acid leakage due to poor
* Conduct a visual inspection for welding of he cover. ○
breakage, deformation, or cracks. (with no damage)
Page 23 of 100
2. Outside damage and 1. Outside damage due to causes
breakage without damage due to ○
* Check with naked eyes. mistreatment.
2. Outside damage due to
○
mistreatment.
3. Damage due to a spark
○
between terminals.
4. Damage and breakage due to
○
heat.
3. Measure the voltage for the Refer to
1. 12.0V ○
battery load test
; but wait at least one day before 2. 11.0V< battery voltage<12.0V Refer to
measuring in case of recharging, ○
due to over-discharge. load test
and recharging should be made in
accordance with the charging 3. Below 11.0V due to charge Refer to
○
instructions. condition failure. load test
4. Below 11.0V due to discharged Refer to
○
for a long period. load test
5. Below 11.0V due to internal Refer to
○
short circuit. load test
4. Load test
; For 15 seconds with a half of the 1. Load test result: below 9.5V ○
CCA electric current value, but the
voltage on the dischaarging stage
should be above 9.6V (27±5°C) Mfg.
- Conduct the test with a battery 2. Load test result: above 9.6V ○ Defect
tester. usable
(Refer to the tester manual)
3. LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow :
A. If the battery has been on charge, remove the surface charge by connect a 300 ampere load for 15 seconds.
B. Connect the voltmeter and apply the specified load.
C. Read the voltage after the load has been applied for 15 seconds.
D. Disconnect the load.
E. Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that
shown in the voltage table.
Page 24 of 100
Voltage Temperature
9.6 20°C (70°F) and above
9.5 16 °C (60 °F)
9.4 10 °C (50 °F)
9.3 4 °C (40 °F)
9.1 -1 °C (30 °F)
8.9 -7 °C (20 °F)
8.7 -12 °C (10 °F)
8.5 -18 °C (0 °F)
- If the voltage is less than shown in the table, the battery is good.
- If the voltage is greater than shown in the table, replace the battery.
BATTERY DIAGNOSTIC TEST (2)

1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.
Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the
electrolyte. Heavy rubber gloves (not the household type) should be worn when removing the battery.
4. Inspect the battery carrier for damage caused by the loss of electrolyte. If acid damage is present, it will be
necessary to clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush
and wipe off with a cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described in Step(3).
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed
cables and broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure the tops of the terminals are flush with the tops of
the posts.
11. Tighten the terminal nuts securely.
Page 25 of 100
12. Coat all connections with light mineral grease after tightening.
When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke
near batteries being charged or which have recently been charged. Do not break live circuits at the
terminals of batteries being charged. A spark will occur when the circuit is broken. Keep open flames
away from the battery.
Engine Electrical System > Charging System > Description and Operation
DESCRIPTION
The charging system included a battery, an generator with a built-in regulator, and the charging indicator light and
wire.
The generator has six built-in diodes (three positive and three negtive), each rectifying AC current to DC current.
Therefore, DC curent appears at generator "B" terminal.
In addition, the charging voltage of this generator is regulated by the battery voltage detection system.
The generator is regulated by the battery voltage detection system. The main components of the generator are the
rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley. The brush holder contains a built-in
electronic voltage regulator.
Engine Electrical System > Charging System > Repair procedures

Page 26 of 100
• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Do not perform tests with a high voltage insulation resistance tester.
• Never disconnect the battery while the engine is running.
CHECK BATTERY VOLTAGE
1. After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine,
turn the ignition switch ON and turn on the electrical system (headlamp, blower motor, rear defogger etc.) for 60
seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage : 12.5~12.9V at 20°C (68°C)
If the voltage is less than specification, charge the battery.

CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
1. Check that the battery terminals are not loose or corroded.
2. Check the fusible link and fuses for continuity.
INSPECT DRIVE BELT
1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it
should be replaced.
Page 27 of 100
2. Using a belt tension gauge, measure the drive belt tension.
DRIVE BELT TENSION
New belt 690~880 N (150~200 lb)
Used belt 340~490 N (77~110 lb)
If the belt tension is not as specified, adjust it.
- "New belt" refers to a belt which has been used less than 5 minutes on a running engine.
- "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
- After installing a belt, check that it fits properly in the ribbed grooves.
- Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the
pulley.
- After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.
VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES

1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the generator while the engine is running.
CHECK DISCHARGE WARNING LIGHT CIRCUIT
1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine. Check that the light goes off.
INSPECT CHARGING SYSTEM
PREPARATION
1. Turn the ignition switch to "OFF".
To find abnormal conditions of the connection, actions should not be taken on the two terminals and each
connection during the test.
Page 28 of 100
2. Connect a digital voltmeter between the generator "B" terminal and battery (+) lead wire to the battery (+)
terminal. Connect the (+) lead wire of the voltmeter to the "B" terminal and the (-) lead wire to the battery (+)
terminal.
CONDITIONS FOR THE TEST

2. Switch on the headlamps, blower motor and so on. And then, read the voltmeter under this condition.
RESULT
1. The voltmeter may indicate the standard value.
0.2V max.
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case
check the wiring from the generator "B" terminal to the fusible link to the battery (+) terminal. Check for loose
connections, color change due to an overheated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle. Turn off the head lamps, blower motor and the ignition
switch.
PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking method is de
scribed in "BATTERY".
The battery that is used to test the output current should be one that has been partially discharged. With a fully
charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the generator drive belt. The belt tension check method is described in the section
"COOLING".
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the generator output wire from the generator "B" terminal.
5. Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire. Be
sure to connect the (-) lead wire of the ammeter to the disconnected output wire.
Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the generator
"B" terminal and (-) lead wire to a good ground.
Page 29 of 100
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.
TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between the generator "B" terminal and battery (-) terminal, a blown fusible link or poor
grounding is suspected.
2. Start the engine and turn on the headlights.
3. Set the headlights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to
2,500 rpm and read the maximum output current value indicated by the ammeter.
After the engine starts up, the charging current quickly drops. Therefore, the above operation must be
done quickly to readthe maximum current value correctly.
RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the generator output wire is in good
condition, remove the generator from the vehicle and test it.
63A min.
• The nominal output current value is shown on the nameplate affixed to the generator body.
• The output current value changes with the electrical load and the temperature of the generator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlights on
the cause discharge of the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the generator itself or ambient
temperature is too high.
In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
4. Remove the ammeter and voltmeter and the engine tachometer.
5. Connect the generator output wire to the generator "B" terminal.
6. Connect the battery ground cable.
PREPARATION
1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. For battery checking method, see "BATTERY".
Check the generator drive belt tension. For belt tension check, see "COOLING" section.
2. Turn ignition switch to "OFF".
Page 30 of 100
4. Connect a digital voltmeter between the "B" terminal of the generator and ground. Connect the (+) lead of the
voltmeter to the "B" terminal of the generator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the generator output wire from the generator "B" terminal.
6. Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire.
Connect the (-) lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.
TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.
Battery voltage
If it reads 0V, there is an open circuit in the wire between the generator "B" terminal and the battery and the
battery (-), or the fusible link is blown.
2. Start the engine. Keep all lights and accessories off.
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the generator output current drops to
10A or less.
RESULT
1. If the voltmeter reading agrees with the value listed in the Regulating Voltage Table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the generator is
faulty.
Regulating Voltage Table
Voltage regulator ambient temperature °C (°F) Regulating voltage (V)
-20 (-4) 14.2 ~ 15.4
20 (68) 14.0 ~ 15.0
60 (140) 13.7 ~ 14.9
80 (176) 13.5 ~ 14.7
2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
4. Remove the voltmeter and ammeter and the engine tachometer.
6. Connect the battery ground cable.
1. Be sure to check the following before testing:
Generator installation and wiring connections
Generator drive belt tension
Fusible link
Abnormal noise from the generator while the engine is running
2. Turn the ignition switch to the OFF position.
3. Disconnect the negative battery cable.
Page 31 of 100
4. Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range
of 0-100A in series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the
ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the disconnected output wire).
An inductive-type ammeter which enables measurements to be taken without disconnecting the generator
output wire is recommended. Using this equipment will lessen the possibility of a voltage drop caused by a
loose "B" terminal connection.
5. Connect a digital-type voltmeter between the generator "B" terminal and the battery (+) terminal. (Connect the
(+) lead of the voltmeter to the "B" terminal. Connect the (-) lead of the voltmeter to the battery (+) cable.
6. Reconnect the negative battery cable.
7. Connect a tachometer or the scan tool.
9. With the engine running at approx. 2500 r/min, turn the headlights and other lights on and off to adjust the
generator load on the ammeter slightly above 30A.
max. 0.3V
When the generator output is high and the value displayed on the ammeter does not decrease to 30A, set
the value to 40A.Read the value displayed on the voltmeter. In this case the limit becomes max. 0.4V.
10. If the value displayed on the voltmeter is still above the limit, a malfunction in the generator output wire may
exist. Check the wiring between the generator "B" terminal and the battery (+) terminal (including fusible link). If
a terminal is not sufficiently tight or if the harness has become discolored due to overheating, repair, the test
again.
11. After the test, run the engine at idle.
12. Turn off all lights and turn the ignition switch to the OFF position.
13. Disconnect the tachometer or the scan tool.
14. Disconnect the negative battery cable.
15. Disconnect the ammeter and voltmeter.
Page 32 of 100
17. Connect the negative battery cable.
Engine Electrical System > Starting System > Schematic Diagrams

CIRCUIT DIAGRAM FOR STARTING SYSTEM
Page 33 of 100
Page 34 of 100
Engine Electrical System > Starting System > Starter > Components and Components Location
COMPONENTS
Page 35 of 100
Engine Electrical System > Starting System > Starter > Repair procedures
REPLACEMENT
1. Disconnect the battery negative cable.
Page 36 of 100
2. Disconnect the starter cable(A) from the B terminal(B) on the solenoid(C), then disconnect the connecto(D) from
the S terminal(E).
3. Remove the 2 bolts holding the starter, then remove the starter.
5. Connect the battery positive cable and negative cable to the battery.
DISASSEMBLY
1. Disconnect the M-terminal(A) on the magnet switch assembly(B).
2. After loosening the 2 screws(A), detach the magnet switch assembly(B).
3. Loosen the brush holder mounting screws(A) and through bolts(B).

Page 37 of 100
4. Remove the rear bracket(A) and brush holder assembly(B).
5. Remove the yoke(A) and armature(B).
6. Remove the, lever plate(A) and planet shaft packing(B).
7. Disconnect the planet gear(A).
8. Disconnect the planet shaft assembly(A) and lever(B).

Page 38 of 100
9. Press the stop ring(A) using s socket(B).
10. After removing the stopper(A) using stopper pliers(B).
11. Disconnect the stop ring(A), overrunning clutch(B), internal gear(C) andplanet shaft(D).
Using a suitable pulling tool(A), pull the overrunning clutch stopring(B) over the
stopper(C).
INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
Page 39 of 100
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage,
replace the armature.
4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the
following specifications, or recondition with #500 or #600 sandpaper (B).
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator diameter
Standard (New) :
M/T : 29.9~30.0 mm (1.177~1.181 in.)
A/T : 28.0 ~ 28.1 mm (1.102~1.106 in.)
Service limit :
M/T : 29.0 mm (1.142 in.)
A/T : 27.5 mm (1.083 in.)
Page 40 of 100
6. Measure the commutator (A) runout.
A. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
B. If the commutator runout is not within the service limit, replace the armature.
Commutator Runout
Standard (New) : 0.02mm (0.001 in.) max.
Service limit : 0.05mm (0.002 in.)
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper
depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow,
too narrow, or V-shaped (D).
Commutator mica depth

Standard (New) :
M/T : 0.5~0.8 mm (0.020~0.031 in.)
A/T : 0.4~0.5 mm (0.016~0.020 in.)
Service limit :
M/T : 0.2mm (0.008 in.)
A/T : 0.15 mm (0.006 in.)
Page 41 of 100
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
9. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and
between the commutator and armature shaft (C). If continuity exists, replace the armature.
INSPECT STARTER BRUSH
STARTER BRUSH HOLDER TEST

1. Check that there is no continuity between the (+) brush holder (A) and (-) brush holder (B). If there is no
continuity, replace the brush holder assembly.
Page 42 of 100
2. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a
spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush.
Spring tension
M/T : 13.7~19.6N (1.4~2.0 kgf, 3.07~4.41 lbf)
A/T : 15.7~17.7 N (1.6~1.8 kgf, 3.53~3.97 lbf)
3. Pry back each brush spring(A) with a screwdrive, then position the brush(B) about halfway out of its holder, and
release the spring to hold it there.
4. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push
the brush down until it seats against the commutator, then release the spring against the end of the brush.
To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the
commutator and each brush, and smoothly rotate the armature. The contact surface of the rushes will be
sanded to the same contour as the commutator.
INSPECT OVERRUNNING CLUTCH

1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
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2. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in
both directions, replace it.
3. If the starter driver gear (B) is worn or damaged, replace the overrunning clutch assembly: the gear is not
available separately.
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the yoke assembly and/or armature will damage the
insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The overrun clutch is pre-lubricated at the factory and solvent
will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
INSPECTION
ARMATURE INSPECTION AND TEST
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage,
4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the
following specifications, or recondition with #500 or #600 sandpaper (B).
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5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator diameter
Standard (New) :
M/T : 29.9~30.0 mm (1.177~1.181 in.)
A/T : 28.0 ~ 28.1 mm (1.102~1.106 in.)
Service limit :
M/T : 29.0 mm (1.142 in.)
A/T : 27.5 mm (1.083 in.)
6. Measure the commutator (A) runout.

A. If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
B. If the commutator runout is not within the service limit, replace the armature.
Commutator Runout
Standard (New) : 0.02mm (0.001 in.) max.
Service limit : 0.05mm (0.002 in.)
Page 45 of 100
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper
depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow,
too narrow, or V-shaped (D).
Commutator mica depth

Standard (New) :
M/T : 0.5~0.8 mm (0.020~0.031 in.)
A/T : 0.4~0.5 mm (0.016~0.020 in.)
Service limit :
M/T : 0.2mm (0.008 in.)
A/T : 0.15 mm (0.006 in.)
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments,
9. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and
between the commutator and armature shaft (C). If continuity exists, replace the armature.
INSPECT STARTER BRUSH

Page 46 of 100
STARTER BRUSH HOLDER TEST

1. Check that there is no continuity between the (+) brush holder (A) and (-) brush holder (B). If there is no
continuity, replace the brush holder assembly.
2. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a
spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush.
Spring tension
M/T : 13.7~19.6N (1.4~2.0 kgf, 3.07~4.41 lbf)
A/T : 15.7~17.7 N (1.6~1.8 kgf, 3.53~3.97 lbf)
3. Pry back each brush spring(A) with a screwdrive, then position the brush(B) about halfway out of its holder, and
release the spring to hold it there.
Page 47 of 100
4. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push
the brush down until it seats against the commutator, then release the spring against the end of the brush.
To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the
commutator and each brush, and smoothly rotate the armature. The contact surface of the rushes will be
sanded to the same contour as the commutator.
INSPECT OVERRUNNING CLUTCH

1. Slide the overrunning clutch along the shaft.
Replace it if does not slide smoothly.
2. Rotate the overrunning clutch (A) both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in
both directions, replace it.
3. If the starter driver gear (B) is worn or damaged, replace the overrunning clutch assembly: the gear is not
available separately.
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
Engine Electrical System > Starting System > Description and Operation
DESCRIPTION
The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch(A/T), ignition
lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion gear overruns.
Page 48 of 100
Engine Electrical System > Starting System > Repair procedures

INSPECTION
START TEST
The air temperature must be between 59 and 100°F (15 and 38°C) before testing.
Recommended procedure :
• Use a starter system tester.
• Connect and operate the equipment in accordance with the manufacturer's instructions.
• Test and troubleshoot as described.
Alternate Procedure :
• Use the following equipment :
- Ammeter, 0~400A
- Voltmeter, 0~20V (accurate within 0.1 volt)
- Tachometer, 0~1,200 rpm
• Hook up a voltmeter and ammeter as shown.
After this test, or any subsequent repair, reset the ECM/PCM to clear any codes.
Check the Starter Engagement :
1. Turn the ignition switch to START (III) with the shift lever in or position (A/T) or with the clutch pedal depressed
(M/T). The starter should crank the engine.
A. If the starter does not crank the engine, go to step 3.
B. If it cranks the engine erratically or too slowly, go to "Check for Wear and Damage" on the next page.
2. Check the battery, battery positive cable, ground, starter cut relay, and the wire connections for looseness and
corrosion. Test again.
If the starter still does not crank the engine, go to step 4.
3. Unplug the connector from the starter.
Page 49 of 100
4. Connect a jumper wire from the battery positive (+) terminal to the solenoid terminal.
The starter should crank the engine.
A. If the starter still does not crank the engine, remove it, and diagnose its internal problem.
B. If the starter cranks the engine, go to step 6.
5. Check the ignition switch (see page EE-14).
6. Check the starter relay (see page EE-47).
7. Check the A/T gear position switch (A/T) or the clutch interlock switch (M/T).
8. Check for an open in the wire between the ignition switch and starter.
If cranking voltage is too low, or current draw too high, check for :
• dead or low battery.
• open circuit in starter armature commutator segments.
• starter armature dragging.
• shorted armature winding.
• excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm.
If speed is too low, check for :
• loose battery or starter terminals.
• excessively worn starter brushes.
• open circuit in commutator segments.
• dirty or damaged helical splines or drive gear.
• defective drive gear overrunning clutch.
Check starter disengagement
With the shift lever in N or P position (A/T) or with the clutch pedal depressed (M/T), turn the ignition switch to
START(III), and release to ON(II).
The starter drive gear should disengage from the torque converter ring gear or flywheel ring gear when you release
the key.
If the drive gear hangs up on the torque converter ring gear or flywheel ring gear, check for :
• solenoid plunger and switch malfunction.
• dirty drive gear assembly or damaged overrunning clutch.
STARTER SOLENOID TEST
Page 50 of 100
1. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). The coil is OK if
there is continuity.
2. Check the pull-in coil for continuity between the S and M terminals. The coil is OK if there is continuity.
FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft jaws and connecta fully-charged 12-volt battery to starter
motor as follows :
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostatas shown is the illustration.
3. Connect a voltmeter (15-volt scale) across starter motor.
4. Rotate carbon pile to the off position.
5. Connect the battery cable from battery's negative post to the startermotor body.
6. Adjust until battery voltage shown on the voltmeter reads 11 volts.
7. Confirm that the maximum amperage is within the specifications andthat the starter motor turns smoothly and
freely :
: Max. 90 Amps
: Min. 2,800 rpm
Engine Electrical System > Cruise Control System > Schematic Diagrams
CIRCUIT DIAGRAM FOR CRUISE CONTROL SYSTEM
Page 51 of 100
Engine Electrical System > Cruise Control System > Components and Components Location
COMPONENTS LOCATION
Page 52 of 100
Engine Electrical System > Cruise Control System > Repair procedures
INSPECTION
CRUISE REMOCON SWITCH TEST
1. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least three minutes.
2. Remove the driver's airbag (See page RT).
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3. Disconnect the remocon switch connector.
4. Check the continuity between the terminals of the connector in each switch position according to the table.
A. If there is continuity, and it matches the table, the switch is O.K.
B. If there is no continuity, replace the remocon switch.
BRAKE SWITCH TEST

1. Disconnect the connector from the brake switch.
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2. Remove the brake switch.
3. Check for continuity between the terminals according to the table.
4. If necessary, replace the switch or adjust the pedal height.
ACTUATOR CABLE ADJUSTMENT

1. Check that the actuator cable (A) moves smoothly with no binding or sticking.
2. position, M/T in neutral) until the radiator fan comes on, then let it idle.
3. Measure the amount of movement of the output linkage (B) until the engine speed starts to increase.
At first, the output linkage should be located at the fully closed position (C). The free play (D) should be
3.75±0.5 mm (0.15±0.02 in.)
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4. If the free play is not within specs, move the cable to the point where the engine speed starts to increase, and
tighten the locknut (A) and adjusting nut (B).
5. Turn the adjusting nut (A) until it is 3.75±0.5 mm (0.15±0.02 in.) away from the bracket (B).
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6. Pull the cable so that the adjusting nut (A) touches the bracket, and tighten the locknut (B).
REPLACEMENT
CRUISE CONTROL UNIT AND CABLE
1. Loosen the locknuts(A) and disconnect the actuator cable (B) from the throttle linkage(C).
2. Disconnect the cruise control unit connector(D).

Page 57 of 100
3. Loosen the three mounting bolts(E), and remove the cruise control unit with the bracket(F).
4. Loosen the locknuts(A) and disconnect the actuator cable(B) from the cruise control unit.

CRUISE REMOCON SWITCH REPLACEMENT
1. Disconnect the battery negative cable, them disconnect the positive cable, and wait at least three minutes.
2. Remove the driver's airbg (See page RT).
3. Disconnect the remocon switch connector(A).
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4. Loosen the two mounting screws(B), and remove the cruise remocon switch.

6. Connect the battery positive cable and negative cable to the battery.
Engine Electrical System > Troubleshooting > P0300

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 59 of 100
Monitoring Strategy ● Multiple misfire
Threshold value ● Misfire rate for FTP E/M thresh > 2%
● Engine speed 360-6240 rpm
● Engine load > Zero torq.
● Vacuum leak in air intake
● Eng. load change < 7-357%/seg
system
● Eng. speed change < 1580 rpm/s
case1 Enable Conditions ● CKPS circuit malfunction
● No rough load < 0.3g
● Ignition circuit malfunction
● 0 sec after engine start
● Faulty ignition coil or pulg wire
● Intake air temperature > -30 degC (-22
● Spark plug malfunction
°F)
● Low compression due to
Diagnostic Time ● 1000 revs blown head gasket, leaking valve
● Misfire rate for catalyst damage > 3.2 ~ or piston ring
Threshold value ● Low/high fuel pressure due to
33%
faulty
● pressure regulator,restricted
fuel lines,plugged fuel filter or
faulty fuel pump
Case2 ● Eng. speed change < 1580 rpm/s ● Fuel injector circuit malfunction
Enable Conditions
● No rough load < 0.3g ● Faulty fuel injector
● Faulty PCM
°F)
Diagnostic Time ● 200 revs
Fail Safe ● Failed cylinder shut off
If any injectors, HO2S, ECTS, and MAP codes are present, do all repairs associated with those codes before
proceeding this troubleshooting guide.
MONITOR DTC STATUS

Page 60 of 100
3. Monitor the "ignition timing" parameter on the scantool.
Specification
Idle : 0 ~ 20° BTDC
3000 rpm : 29 ~ 49° BTDC

damage.

1. Ignition "OFF"
2. Disconnect ignition coil connector.
Page 61 of 100
4. Measure voltage between terminal 1 of sensor harness connector and chassis ground.
Open or Short circuit to chassis ground between ignition coil harness connector and ignition switch harness
connector.
Repair as necessary and go to "Verification Vehicle Repair" procedure.
In case,when ignition connector is disconnected,the voltage at terminal 1 is 0V.

Possible cause : Open or short circuit of battery line between FUSE 10(10A) of P/C-J/BOX and
terminal 1 of ignition coil.

1. Check for CKPS signal
(1) Engine "ON"
(2) Monitor waveform at the terminal 1 of CKPS.
(3) Is the wave form displayed normally?
Go to "P0335 Crankshaft position sensor - no signal" procedure.

SYSTEM INSPECTION
Page 62 of 100
1. Check for fuel pressure
(1) Reduce the internal pressure of the fuel pipe and hoses and cover the hose connection with a shop towel to
prevent splashing of fuel.
(2) Remove the bolt connecting the fuel line to the fuel delivery pipe.
(3) Using the fuel pressure gauge adaptor,install the fuel pressure gauge to the fuel pressure gauge adaptor.
(4) Apply battery voltage to the terminal for thwe pump drive and activate the fuel pump:then,with fuel pressure
applied,check fuel leakage from the pressure gauge or connection part.
(5) Start an engine and warm up to operating temperature.
(6) Check for fuel pressure at idle.
(7) Is fuel pressure within specification?
Go to "Compression test " as below.
Check fuel delivery system.

2. Compression test
(1) Perform compression test at 300rpm.
Perform leak down test to determine source of low compression.

Page 63 of 100
1. Check for ignition coil and plug wires
(1) Turn ignition switch to OFF and disconnect ignition coil connector.
(2) Check ignition coil and plug wires for cracks or carbon tracing.
(3) Check resistance of primary coil.
(4) Check resistance of secondary coil.

(5) Check for resistance of plug wires.
(6) Is the resistance of ignition coils and plug wires within specification?
Go to "Check for spark plug " as below.
Faulty ignition coils or plug wires.

2. Check for spark plug
Check the following items below for spark plug.
(1) Remove spark plugs and check gap and plug condition.
(2) Check the electrode condition(wear or carbon deposit)
(3) Check the insulators condition(crack,etc)
(4) Check the carbon deposit
(5) Are spark plugs gapped properly and in good condition?
Go to "Check for vacuum and PCV " as below.
Fauity spark plugs.

Page 64 of 100
3. Check for vacuum and PCV
Check for any split, disconnected or perforated vacuum hoses. Also, check PCV valve for proper operation.
(1) Remove the positive crankcase ventilation valve.
(2) Insert a thin stick into the positive crankcase ventilation valve from the threaded side to check that the plunger
moves.
(3) If the plunger does not move,the positive crankcase ventilation valve is clogged.Clean or replace it.
(4) Are vacuum hoses and PCV okay?
Go to "System inspection" procedure.
Replace faulty vacuum hoses or PCV.


SCHEMATIC DIAGRAM
Page 65 of 100

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 66 of 100
onitoring Strategy ● Crankshaft speed fiuctuation
system
°F)
33%
faulty
faulty fuel pump
Enable Conditions
● Faulty PCM
°F)
MONITOR DTC STATUS

Page 67 of 100
Specification
3000 rpm : 29 ~ 49° BTDC

damage.

1. Ignition "OFF"
Page 68 of 100
connector.


(1) Engine "ON"

SYSTEM INSPECTION
Page 69 of 100

2. Compression test

Page 70 of 100


Fauity spark plugs.

Page 71 of 100
moves.


SCHEMATIC DIAGRAM
Page 72 of 100

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 73 of 100
system
°F)
33%
faulty
faulty fuel pump
Enable Conditions
● Faulty PCM
°F)
MONITOR DTC STATUS

Page 74 of 100
Specification
3000 rpm : 29 ~ 49° BTDC

damage.

1. Ignition "OFF"
Page 75 of 100
connector.


(1) Engine "ON"

SYSTEM INSPECTION
Page 76 of 100

2. Compression test

Page 77 of 100


Fauity spark plugs.

Page 78 of 100
moves.


SCHEMATIC DIAGRAM
Page 79 of 100

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 80 of 100
system
°F)
33%
faulty
faulty fuel pump
Enable Conditions
● Faulty PCM
°F)
MONITOR DTC STATUS

Page 81 of 100
Specification
3000 rpm : 29 ~ 49° BTDC

damage.

1. Ignition "OFF"
Page 82 of 100
connector.


(1) Engine "ON"

SYSTEM INSPECTION
Page 83 of 100

2. Compression test

Page 84 of 100


Fauity spark plugs.

Page 85 of 100
moves.


SCHEMATIC DIAGRAM
Page 86 of 100

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 87 of 100
system
°F)
33%
faulty
faulty fuel pump
Enable Conditions
● Faulty PCM
°F)
MONITOR DTC STATUS

Page 88 of 100
Specification
3000 rpm : 29 ~ 49° BTDC

damage.

1. Ignition "OFF"
Page 89 of 100
connector.


(1) Engine "ON"

SYSTEM INSPECTION
Page 90 of 100

2. Compression test

Page 91 of 100


Fauity spark plugs.

Page 92 of 100
moves.


SCHEMATIC DIAGRAM
Page 93 of 100

GENERAL DESCTIPTION
DTC DESCRIPTION

Page 94 of 100
Monitoring
● Signal check Low
Strategy
Threshold
● Voltage : < 10V ● Open in control circuit
value
(pin 14)
Enable
● 120 sec after engine start ● Charging system
Conditions
● Faulty PCM
Diagnostic
● 0.2 sec
Time
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "Battery voltage" parameter on the scantool.
Specification
Engine stop : 11 ~ 13V
Idle : 12 ~ 15V
Vehicle Repair" proceduredure.

Page 95 of 100
damage.

1. Check for open in harness(control relay power)
(1) Ignition "OFF"
(2) Disconnect the main relay.
(4) Measure voltage between terminal 2 and 5 of main relay harness connector and chassis ground.
Go to "Check for open in harness(main relay control) " as below.
Check for open in power harness.

In case the voltage at terminal 2 and 5 of main relay power line is 0V.
Possible cause : Opne circuit in main relay power line which goes to main relay terminal 2 and 5
through PCM fuse(20A) in E/C-J/BOX
Page 96 of 100
2. Check for open in harness(control relay control)
(1) Ignition "OFF"
(2) Connect PCM connector.
(4) Measure voltage between terminal 14 of PCM harness connector and chassis ground.
Check for open in control harness.

1. Check control relay
(1) Ignition "OFF"
(2) Disconnect the control relay
(3) Apply 12V and a ground to 1 and 2 terminals of the control relay
(4) Measure resistance between terminal 1 and 5 of relay connector(To sensor side)
(5) Does each resistance indicate continuity circuit?
Substitute with a known-good PCM and check for proper operation. If the problem is corrected,replace
Substitute with a known-good control relay and check for proper operation. If the problem is corrected,
replace control relay and then go to "Verification of Vehicle Repair" procedure.

Page 97 of 100
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
Page 98 of 100
DTC DESCRIPTION

Monitoring
● Signal check, high
Strategy
Threshold value ● Voltage : > 17V
Enable ● Vehicle speed > 25 kph(15.53428 ● Charging system
Conditions mile) ● Faulty PCM
Diagnostic
● 0.2 sec
Time
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "Battery voltage" parameter on the scantool.
Specification
Engine stop : 11 ~ 13V
Idle : 12 ~ 15V

Page 99 of 100

damage.

1. Check for generator voltage charging
(1) Engine "ON"
(2) Measure voltage between generator B+ and chassis ground.
Over charging or bad connection of generator


SCHEMATIC DIAGRAM
Page 100 of 100
Page 1 of 98
ACCENT(LC) > 2005 > G 1.5 SOHC > Engine Mechanical System
Engine Mechanical System > General Information > General Information

SPECIFICATIONS
SPEC LIMIT
General
Type In-line, SOHC
No. of cylinder 4
Bore 75.5 mm (2.97 in.)
Stroke 83.5 mm (3.29 in.)
Total displacement 1495 cc
Compression ratio 10.0
Firing order 1-3-4-2
Valve timing
Intake valve opens (BTDC) 12°
Intake valve closes (ABDC) 52°
Exhaust valve opens (BBDC) 52°
Exhaust valve closes (ATDC) 12°
Valve overlap 24°
Cylinder head
Flatness of gasket surface Max. 0.03 mm (0.0012 in.) 0.08 mm (0.00315 in.)
Flatness of manifold mount'g surface Max. 0.15 mm (0.0059 in.) 0.3 mm (0.0118 in.)
Dimension for reworking oversize valve seat
hole
Intake
0.03 O.S. 28.8 ~ 28.821 mm (1.134 ~ 1.135 in.)
0.06 O.S. 29.1 ~ 29.121 mm (1.146 ~ 1.1467 in.)
Exhaust
0.03 O.S. 34.3 ~ 34.325 mm (1.350 ~ 1.351 in.)
0.06 O.S. 34.6 ~ 34.625 mm (1.362 ~ 1.363 in.)
Valve guide hole diameter (intake/exhaust)
0.05 O.S. 11.05 ~ 11.068 mm (0.435 ~ 0.436 in.)
0.25 O.S. 11.25 ~ 11.268 mm (0.443 ~ 0.4436in.)
0.50 O.S. 11.50 ~ 11.518 mm (0.453 ~ 0.4535in.)
Camshaft
Cam height intake 42.8575 mm (1.687 in.) 42.3575 mm (1.667 in.)
Cam height exhaust 42.7354 mm (1.682 in.) 42.2624 mm (1.664 in.)
Journal diameter 30 mm (1.181 in.)
Bearing oil clearance 0.045 ~ 0.085 mm (0.0018 ~ 0.0033 in.)
End play 0.07 ~ 0.28 mm (0.0027 ~ 0.011 in.)
Crankshaft
Journal diameter 50 mm (1.97 in.)
Pin diameter 45 mm (1.77 in.)
Bend 0.03 mm (0.0018 in.)
Out of roundness of journal and pin Max. 0.005
Taper of journal and pin Max. 0.005
End play 0.05 ~ 0.175 mm (0.002 ~ 0.007 in.) 0.25 mm (0.0098 in.)
Page 2 of 98
Undersize of Pin
0.25 44.725 ~ 44.740 mm (1.76 ~ 1.761 in.)
0.50 44.475 ~ 44.490 mm (1.75 ~ 1.751 in.)
0.75 44.225 ~ 44.240 mm (1.74 ~ 1.741 in.)
Undersize of Journal
0.25 49.727 ~ 49.742 mm (1.957 ~ 1.958in.)
0.50 49.477 ~ 49.492 mm (1.948 ~
0.75 1.9485in.)
Main bearing oil clearance 49.227 ~ 49.242 mm (1.938 ~
No. 1,2,4,5 1.9386in.) 0.1 mm (0.00394 in.)
No. 3.
0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in.)
0.028 ~ 0.046 mm (0.0011 ~ 0.0018 in.)
Valve
Stem diameter
Intake 5.955 ~ 5.97 mm (0.2344 ~ 0.2350 in.)
Exhaust 5.95 ~ 5.965 mm (0.2342 ~ 0.2348 in.)
Face angle 45° ~ 45.5°
Thickness of valve head (margin)
Intake 1.1 mm (0.043 in.) 0.8mm (0.031in.)
Exhaust 1.4 mm (0.055 in.) 1.1 mm (0.043 in.)
Valve stem to valve guide clearance
Intake 0.03 ~ 0.06 mm (0.0012 ~ 0.0024 in.) 0.1 mm (0.0039 in.)
Exhaust 0.035 ~ 0.065 mm (0.0014 ~ 0.0026 in.) 0.15 mm (0.006 in.)
Valve guide
Length
Intake 42.7 mm (1.681 in.)
Exhaust 39.1 mm (1.539in.)
Service oversize 0.05, 0.25, 0.50
Valve seat
Width of seat contact
Intake 0.8 ~ 1.2 mm (0.031 ~ 0.047 in.)
Exhaust 1.3 ~ 1.7mm (0.051 ~ 0.067 in.)
Seat angle 45°
Service oversize 0.3, 0.6
Valve spring
Free length (Installed height) 42.03 mm (1.655 in.)
Load 24.7 kg / 34.5 mm
Out of squareness Max 1.5
Cylinder block
Cylinder bore 75.5 ~ 75.53 mm (2.9724 ~ 2.9736 in.)
Out of roundness of cylinder bore Max. 0.01
Taper of cylinder bore -
Flatness of gasket surface Max. 0.05 0.1 mm (0.0039 in.)
Piston
Dameter 75.47 ~ 75.50 mm (2.9713 ~ 2.9724 in)
Piston to cylinder clearance 0.02 ~ 0.04 mm (0.0078 ~ 0.00157 in.)
Piston ring
Page 3 of 98
No. of rings per piston 3
Compression ring 2
Oil ring 1
Compression ring type
No. 1 Inside bevel type, steel
No. 2 Taper type
Oil ring type 3-piece type
Side clearance
No. 1 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) 0.1 mm (0.00394 in.)
No. 2 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) 0.1 mm (0.00394 in.)
Oil ring 0.06 ~ 0.15 mm (0.0023 ~ 0.006 in.)
End gap
No. 1 0.20 ~ 0.35 mm (0.0079 ~ 0.0138 in.) 1 mm (0.0394 in.)
No. 2 0.37 ~ 0.52 mm (0.015 ~ 0.02 in.) 1 mm (0.0394 in.)
Oil ring side rail 0.2 ~ 0.7 mm (0.008 ~ 0.028 in.) 1 mm (0.0394 in.)
Sevice oversize 0.25, 0.50
Connecting rod
Bend Max. 0.05 per 100 mm
Twist Max. 0.1 per 100mm
Connecting rod big end to crankshaft side 0.10 ~ 0.25 mm (0.004 ~ 0.01 in.) 0.4mm(0.016in.)
clearance
Piston pin press in load 1000 ± 500 kg
Bearing oil clearance 0.018 ~ 0.036 mm (0.0007 ~ 0.0014 in.) 0.1mm(0.0039in.)
Flywheel
Runout 0.1mm 0.13mm
(0.0014 in.) (0.005in.)
Oil pressure at curb idle speed (oil temp. 1.5kg/cm²
90~110°C)
Oil pump
Clearance between outer circum ference 0.12 ~ 0.18 mm (0.0047 ~ 0.0071 in.)
and front
Clearance between roter axial side and front 0.04 ~ 0.087 mm (0.0016 ~ 0.0034 in.)
case
Tip clearance between outer and inner roter 0.025 ~ 0.069 mm (0.0010 ~ 0.0027 in.)
Relief spring
Free length 46.6 mm (1.8346 in.)
Load 6.1kg at 40.1 mm (13.4216 at 1.578 in.)
Cooling method Water-cooled, Pressurized, Forced
circulation with electrical fan
Cooling sys. Quantity 6.5 lit (6.87 U.S. qut, 5.72 lmp qts)
Thermostat
Type Wax pellet type with jiggle valve
Normal opening temp. 82°C
Opening temp. range 80.5 ~ 83.5°C
Wide opening temp. 95°C
Page 4 of 98
Radiator cap
Main valve opening pressure 86.1 ~ 124.5 kpa
Main valve colseing pressure 83.4 kpa
Vacuum valve opening preesur -86.6 kpa
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension sys. Rubber hanger type
TIGHTENING TORQUE
Item Nm kg.cm lb.ft
Cylinder Block
Left engine support bracket bolt 30 ~ 42 300 ~ 420 22 ~ 31
Oil pressure switch 13 ~ 15 130 ~ 150 9.6 ~ 11
Cylinder head
Cylinder head bolt (23 ~ 27) + (230 ~ 270) + (17 ~ 20) +
(60 + 60°) (60° + 60°) (60° + 60°)
Intake/manifold bolts or nuts 15 ~ 20 150 ~ 200 11 ~ 15
Exhaust manifold nut 15 ~ 20 150 ~ 200 11 ~ 15
Recker cover bolt 8 ~ 10 80 ~ 100 6~7
Recker arm shaft bolt 20 ~ 27 200 ~ 270 15 ~ 18
Rear plate bolt 8 ~ 10 80 ~ 100 6~7
Main Moving parts
Connecting rod cap nut 32 ~ 35 320 ~ 350 24 ~ 26
Crankshaft bearing cap bolt 55 ~ 60 550 ~ 600 41 ~ 44
Flywheel M/T bolt 130 ~ 140 1300 ~ 1400 96 ~ 103
Drive plate A/T bolt 130 ~ 140 1300 ~ 1400 96 ~ 103
Timing Belt
Crankshaft sprocket bolt 140 ~ 150 1400 ~ 1500 103 ~ 111
Camshaft sprocket bolt 80 ~ 100 800 ~ 1000 59 ~ 74
Timing belt tensioner bolt 20 ~ 27 200 ~ 270 15 ~ 20
Timing belt cover bolt 10 ~ 12 100 ~ 120 7~9
Front case bolt 12 ~ 15 120 ~ 150 9 ~ 11
Engine Mounting
Engine mounting insulator bolt 90 ~ 110 900 ~ 1100 66.4 ~ 81.1
Engine mounting bracket to engine nuts and bolts 50 ~ 65 500 ~ 650 36.9 ~ 48.0
Transaxle mount insulator bolt
Transaxle insulator bracket to side member bolts 90 ~ 110 900 ~ 1100 66.4 ~ 81.1
Front roll stoper insulator bolt 30 ~ 40 300 ~ 400 22.1 ~ 29.5
Front roll stoper bracket to sub-frame bolt
Rear roll stoper insulator bolt 45 ~ 60 450 ~ 600 33.2 ~ 44.3
Rear roll stoper bracket to sub-frame bolt 30 ~ 40 300 ~ 400 22.1 ~ 29.5
45 ~ 60 4520 ~ 600 33.2 ~ 44.3
30 ~ 40 300 ~ 400 22.1 ~ 29.5
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Oil filter 12 ~ 16 120 ~ 160 9 ~ 12
Oil pan bolts 10 ~ 12 100 ~ 120 7~9
Oil pan drain plug 40 ~ 45 400 ~ 450 30 ~ 33
Oil screen bolts 15 ~ 22 150 ~ 220 11 ~ 16
Timing belt upper cover bolts 10 ~ 12 100 ~ 120 7~9
Timing belt lower cover bolts 10 ~ 12 100 ~ 120 7~9
Surge tank to inlet manifold nuts and bolts 15 ~ 20 150 ~ 200 11 ~ 15
Alternator support and nut 20 ~ 25 200 ~ 250 15 ~ 18
Alternator lock bolt 15 ~ 22 150 ~ 220 11 ~ 16
Alternator brace mounting bolt 20 ~ 28 200 ~ 280 15 ~ 21
Cooling system
Coolant pump pulley 8 ~ 10 80 ~ 100 6~7
Coolant pump bolt 12 ~ 15 120 ~ 150 9 ~ 11
Coolant temperature gauge unit 10 ~ 12 100 ~ 120 7~9
Coolant temperature sensor 15 ~ 20 150 ~ 200 11 ~ 15
Coolant outlet fitting bolt 17 ~ 20 170 ~ 200 13 ~ 15
Thermostat housing bolt 15 ~ 20 150 ~ 200 11 ~ 15
Intake and Exhaust system
Air cleaner body mounting bolts 8 ~ 10 80 ~ 100 6~7
Resonator mounting bolts 4~6 40 ~ 60 2.9 ~ 4.3
Throttle body to surge tank bolts 15 ~ 20 150 ~ 200 11 ~ 15
Oxygen sensor to exhaust manifold 50 ~ 60 500 ~ 600 37 ~ 44
Front exhaust pipe to exhaust manifold nuts 30 ~ 40 300 ~ 400 22 ~ 30
Front exhaust pipe bracket bolts 30 ~ 40 300 ~ 400 22 ~ 30
Front exhaust pipe to cataiytic converter bolts 40 ~ 60 400 ~ 600 30 ~ 44
SELECTION OF ENGINE OIL

Page 6 of 98
For best performance and maximum protection of all types of operation, select only those lubricants which:
1. Satisfy the requirements of the API classification.
2. Have proper SAE grade number for expected ambient temperature range.
Lubricant that does not have both an SAE grade number and an API service classification on the container should
not be used.
MAINTENCE
CHECKING ENGINE OIL
1. Position the vehicle on a level surface.
2. Warm up the engine.
If a vehicle has been out of service for a prolonged period of time, warm up the engine for approximately
20 minutes.
3. Turn off the engine, and wait 2 or 3 minutes, then check the oil level.
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4. Check that the engine oil level is within the level range indicated on the oil dipstick if the oil level is found to have
fallen to the lower limit (the "L" mark), refill to the "F" mark.
When refilling, use the same type of engine oil.

5. Check that the oil is not dirty or contaminated with coolant or gasoline and that it has proper viscosity.
CHANGING ENGINE OIL
Be careful not to burn yourself, the engine oil is hot.

1. Run the enigne until it reaches normal operating temperature.
2. Turn off the engine.
3. Remove the oil filler cap and the engine oil drain plug. Drain the engine oil.
4. Install and tighten the drain plug to the specified torque.
Tightening torque
Drain plug : 40 ~ 45 Nm (400 ~ 450 kg.cm, 30 ~ 33 lb.ft)
Whenever tightening the oil drain plug, use a new drain plug gasket.
5. Fill the crankcase with fresh engine oil through the oil filler cap opening.
Drain and Refill Without oil filter :

3.0 liter (3.17 U.S. qts., 2.64 lmp. qts.)
Drain and Refill With oil filter :
3.3 liter (3.48 U.S. qts., 2.90 lmp. qts.)
6. Install the oil filler cap.

7. Start and run the engine.
8. Turn off the engine and then check the oil level. Add oil if necessary.
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FILTER SELECTION
All Hyundai engines are dquipped with a high quality, disposable oil filter. This filter is recommended as a
replacement filter on all vehicles. The quality of replacement filters varies considerably. Only high quality filters
should be used to assure the most efficient service. Make sure that the rubber gasket from the old oil filter is
completely removed from the contact surface on the engine block or front case before installing the new filter.
PROCEDURE FOR REPLACING THE OIL FILTER
Be careful not to burn yourself, the engine and engine oil are hot.
1. Use a filter wrench to remove the oil filter.
2. Before installing the new oil filter on the engine clean oil filter sealing baseplate with shop towel.
Apply engine oil to the surface of rubber packing.
3. Tighten the oil filter to the specified torque.
Tightening torque
Oil filter : 12 ~ 16 Nm (120 ~ 160 kg.cm, 9 ~ 12 lb.ft)
4. Run the engine to check for engine oil leaks.

5. After turning off the engine, check the oil level and add oil as necessary.
CHECKING COOLANT LEAK
1. Wait until the engine is cool, then carefully remove the radiator cap.
2. Confirm that the coolant level is up to the filler neck.
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3. Install a radiator cap tester to the radiator filler neck and apply 140 KPa (1.4 kg/cm², 20 psi) pressure. Hold it
for two minutes in that condition, while checking for leakage from the radiator, hoses or connections.
1. Radiator coolant may be extremely hot. Do not open the system because hot, or scalding water could
gush out causing personal injury. Allow the vehicle to cool before servicing this system.
2. Be sure to clean away any moisture from the places checked completely.
3. When the tester is removed, be careful not to spill any coolant.
4. Be careful when installing and removing the tester and when testing do not deform the filler neck of the
radiator.
4. If there is leakage, repair or replace with the apropriate part.
RADIATOR CAP PRESSURE TEST

1. Remove the radiator cap. Wet its seal with engine coolant, then install it on the tester.
2. Increase the pressure until the gauge stops moving.
Main valve opening pressure :

78 ~ 108 kPa (0.8 ~ 1.1 kg/cm², 11.3 ~ 15.6 psi)
Limit : 65 kPa (0.66 kg/cm², 9.2 psi)
3. Check that the pressure level is maintained at or above the limit.

4. Replace the radiator cap if the reading does not remain at or above the limit.
Be sure that the cap is clean before testing. Rust or other foreign material on the cap seal will cause an
incorrect reading.
CHANGING ENGINE COOLANT
When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on electrical parts or the
paint. If any coolant spills, rinse it off immediately.
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1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to the
touch.
2. Remove the radiator cap.
3. Loosen the drain plug and drain the coolant.
4. Tighten the radiator drain plug securely.

5. Remove, drain and reinstall the reservior.
Fill the tank halfway to the MAX mark with water, then up to the MAX mark with antifreeze.
6. Pour coolant into the radiator up to the base of the filler neck, and install the radiator cap loosely.
7. Start the engine and let it run until it warms up (the radiator fan comes on at least twice)
8. Turn off the engine. Check the level in the radiator, add coolant if needed.
9. Put the radiator cap on tightly, then run the engine again and check for leaks.
SPECIFIC GRAVITY TEST
1. Measure the specific gravity of the coolant with a hydrometer.
2. Measure the coolant temperature and calculate the concentration from the relation between the specific gravity
and temperature, using the following table for reference.
RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY
Coolant temperature °C (°F) and specific gravity Coolant

Freezing Safe operating
concentration
temperature °C temperature °C
(Specific
10 (50) 20 (68) 30 (86) 40 (104) 50 (122) (°F) (°F)
volume)
1.054 1.050 1.046 1.042 1.036 -16 (3.2) -11 (12.2) 30%
1.063 1.058 1.054 1.049 1.044 -20 (-4) -15 (5) 35%
1.071 1.067 1.062 1.057 1.052 -25 (-13) -20 (-4) 40%
1.079 1.074 1.069 1.064 1.058 -30 (-22) -25 (-13) 45%
1.087 1.082 1.076 1.070 1.064 -36 (-32.8) -31 (-23.8) 50%
1.095 1.090 1.084 1.077 1.070 -42 (-44) -37 (-35) 55%
1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (-49) 60%
Page 11 of 98
• If the concentration of the coolant is below 30%, its anti-corrosion properties will be adversely
affected.
• If the concentration is above 60%, both the antifreeze and engine cooling property will decrease,
affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the
specified range.
• Do not mix with another brand's product.
RECOMMENDED COOLANT
Antifreeze Mixture ratio of anti freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM 50% [Except tropical areas]
40% [Tropical areas]
CHECKING COMPRESSION PRESSURE

1. Befor checking engine compression, check the engine oil level. Also check that the starter motor and battery are
all in normal operating condition.
2. Check the DTC's. Resetting the ECM will erase any stored DTC's.
3. Start the engine and wait until engine coolant temperature reaches 80~95°C (176~205°F).
4. Disconnect the fuel pump connector.
5. Turn off engine and disconnect the spark plug cables.
6. Remove the spark plug.

7. Disconnect the ignition coil connector.
8. Crank the engine to remove any foreign material in the cylinders.
9. Insert the compression gauge into the spark plug hole.
10. Depress the accelerator pedal to open the throttle fully.

11. Crank the engine and read the gauge.
Standard value : 1500 kpa (15.5 kg/cm², 220 psi)

Limit : 1200 kpa (12.5 kg/cm², 178 psi)
Page 12 of 98
12. Repeat steps 9 to 11 on all cylinders, ensuring that the pressure differential for each of the cylinders is within the
specified limit.
Limit :
Max. 150 kpa (1.5 kg/cm², 21 psi) between cylinders
13. If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil through
the spark plug hole, and repeat steps 9 to 12.
A. If the addition of oil makes the compression toincrease, it is likely that there may be wear between the piston
ring and cylinder wall.
B. If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder
head gasket are all possible causes.
Tightening torque
Spark plug : 20~30 Nm (200~300 kg.cm, 14~22 lb.ft)
ADJUSTING TIMING BELT TENSION

1. Turn the steering wheel fully counter clock wise.
2. Lift the vehicle by using of jack.
3. Remove the engine support bracket.
4. Loosen the coolant pump pulley mounting bolt and loosen the generator belt tension adjustment bolt.
5. Remove the coolant pump pulley, generator belt, power steering pulley and power steering belt.
Page 13 of 98
6. Remove the timing cover upper side mounting bolt.
7. Remove the crankshaft pulley.
8. Turn crankshaft clockwise until enginder number 1 is at top clead center of its compression stroke.
Turn the crankshaft clockwise. If turned counter clockwise, tension is not set.
9. Loosen the tensioner bolt 1 ~ 2 turns and allow tensioner spring to tension the belt.
Page 14 of 98
10. Turn crankshaft clockwise as much as two camshaft sprocket teeth.
11. Tighten the tensioner bolt of slot side of first and then tighten the bolt of pivot side.
12. Check to make sure timing marks line up.
13. Check the tension of timing belt.
When the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force
[approx. 49N (11 lb)], the timing belt log end is approx. half of the tensioner mounting bolt head radius away
from the bolt head center.
14. Install the timing belt cover.
Tightening torque :
10 ~ 12 Nm (100 ~ 120 kg.cm, 7.2 ~ 8.7 lb.ft)
15. Install the crankshaft pulley.

16. Install the coolant pump pulley.
17. Install V-belt and adjust the belt tension.
ADJUSTING DRIVE BELT TENSION
1. Check that the belts are not damaged and are properly fit for the pulley grooves.
2. Apply 100 N (22 lbs.) force to the back and midway portion of the belt between the pulleys as shown in the
illustration. Measure the amount of deflection with a tension gauge.
1. When installing the V-ribbed belt, check that the V-ribs are properly aligned.
2. If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact
surface, and check the pulley for scoring. Also check the amount that the belt is deflected.
STANDARD VALUE :
Adjustment
Items
New Used
For alternator Deflection mm (in.) 7.5 ~ 9.0 (0.29 ~ 0.35) 10 (0.39)
Page 15 of 98
1. The belt tension must be measured half - way between the specified pulleys.
2. When a new belt is installed, adjust the tension to the central value of the standard range indicated
under "New" in the above table. Let the engine idle for 5 minutes or more, and check the standard
value indicated under "Inspection".
3. When adjusting a belt which has been used, or newly installed, after 5 minutes or more of operation,
refer to the standard value indicated under "Used" in the above table.
4. Refer to the standard value indicated under "Inspection" for periodic inspections.
TYPE A TENSION GAUGE
TYPE B TENSION GAUGE

1. When measuring, turn the reset button in the direction of the arrow and set the gauge needle to the RESET
position.
2. If the tension gauge is removed from the belt, the needle will still indicate the tension. Read the tension value after
removing the gauge.
ADJUSTING THE ALTERNATOR BELT
If the belt is too loose, it will cause noise or sudden wear.

If the belt is too tight, the engine coolant pump bearing or the alternator can get damaged.
1. Loosen the alternator nut "A" and the tension adjuster lock bolt "B"
2. Using the tension adjuster bolt, adjust the belt tension to the specification.
3. Tighten the adjuster lock bolt "B".
4. Tighten the alternator nut "A".
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5. Check the tension or the deflection of belt, readjust if necessary.
Tightening torque
Alternator support nut A :
20 ~ 25 Nm (200 ~ 250 kg.cm, 15 ~ 18 lb.ft)
Alternator lock bolt B :
15 ~ 22 Nm (150 ~ 220 kg.cm, 11 ~ 16 lb.ft)
Alternator brace mounting bolt :
20 ~ 28 Nm (200 ~ 280 kg.cm, 15 ~ 21 lb.ft)
Engine Mechanical System > General Information > Special Service Tools
SPECIAL TOOLS
Crankshaft front oil seal installer Installation of the crankshaft front oil seal
09231 - 22000 (use with 09231 - 22100)
Crankshaft front oil seal guide Installation of the crankshaft front oil seal
09231 - 22100 (use with 09231 - 22000)
Camshaft oil seal installer Installation of the camshaft oil seal

09221 - 21000 (use with 09221 - 21100)
Camshaft oil seal guide Used as a guide when pressing in the

09221 - 21100 camshaft oil seal
(use with 09221 - 21000)
Valve spring remover and Removal and installation of the inlet or

installer exhaust valve
09222 - 28000
09222 - 28100
Valve stem oil seal installer

09222 - 22001
Page 17 of 98
Valve stem oil seal installer Installation of the valve stem oil seal
09222 - 22001
Valve guide installer Removal and installation fo the valve guide

09221 - 3F100 A/B
Crankshaft rear oil seal installer 1) Installation of the engine rear oil seal
09231 - 21000 2) Installation of the crankshaft rear oil
seal
Leak down tester Leak down test of auto lash adjuster

09246 - 32000
Engine Mechanical System > General Information > Troubleshooting

TROUBLE SHOOTING
Low compression Blown cylinder head gasket Replace gasket
Worn or damaged piston rings Replace rings
Worn piston or cylinder Repair or replace the piston and/or
cylinder block
Worn or damaged valve seat Repair or replace the valve and/or seat
ring
Low oil pressure Low engine oil level Check engine oil level
Faulty oil pressure switch Replace
Clogged oil filter Replace
Worn oil pump gears or cover Replace
Thin or diluted engine oil Change and find out cause
Oil relief valve stuck (open) Repair
Excessive bearing clearance Replace
High oil pressure Oil relief valve stuck (closed) Repair
Excessive engine Loose engine roll stopper (front, rear) Retighten
vibration Loose transaxle mount bracket Retighten
Loose engine mount bracket Retighten
Loose center member Retighten
Page 18 of 98
Broken transaxle mount insulator Replace
Broken engine mount insulator Replace
Broken engine roll stopper insulator Replace
Noisy valves Thin or diluted engine oil (Low oil pressure) Change
Worn or damaged valve stem or valve guide Replace
Connecting rod and Insufficient oil supply Check engine oil level
main bearing noise
Thin or diluted engine oil Change and find out cause
Excessive bearing clearance Replace
Timing belt noise Incorrect belt tension Adjust belt tension
Low coolant level Leakage of coolant
1. Heater or radiator hose Repair or replace parts
2. Faulty radiator cap Tighten or replace clamps
3. Thermostat housing Replace the gasket or housing
4. Radiator Repair or replace
5. Engine coolant pump Replace parts
Clogged radiator Foreign material in coolant Replace coolant
Abnormally high Faulty thermostat Replace parts
coolant temperature
Faulty radiator cap Replace parts
Restricted flow in cooling system Clear restriction or replace parts
Loose or missing drive belt Adjust or replace
Faulty water pump Replace
Faulty temperature sensor or wiring Repair or replace
Faulty electric fan Repair or replace
Insufficient coolant Refill coolant
Abnormally low Faulty thermostat Replace
coolant temperature
Faulty temperature sensor or wiring Replace or repair
Leakage from oil Loose connections Replace
cooling system Cracked or damaged ; hoses, pipes or oil cooler Replace or repair
Inoperative electrical Damaged : Thermo sensor, Electrical motor, Replace or repair
cooling fan Radiator fan relay, Wiring
Exhaust gas leakage Loose connections Retighten
Broken pipe or muffler Repair or replace
Abnormal noise Detached baffle plate in muffler Replace
Broken rubber hanger Replace
Pipe or muffler contacting vehicle body Correct
Broken pipe or muffler Repair or replace
Page 19 of 98
Engine Mechanical System > General Information > Repair procedures

ENGINE AND TRANSAXLE ASSEMBLY
REMOVAL
1. Remove the battery.
Make sure jacks and safety stands are placed properly and hoist brackets are attached to the correct
position on the engine.
Use fender covers to avoid damaging painted surface.
2. Detach the air cleaner.

Page 20 of 98
3. Disconnect the backup lamp and engine harness connectors.
4. Disconnect the engine ground.

Page 21 of 98
5. Disconnect the alternator connector.
6. Disconnect the connectors for the rear Oxygen sensor harness and the ignition coil harness.
7. Disconnect the coolant temperature sensor and No.1 TDC sensor connector.
Page 22 of 98
8. Disconnect the brake booster vacuum hose.
9. Remove the main fuel line and the return and vapor hoses form the engine side.
To reduce the residual pressure in the hoses, refer to Group Fuel System "Fuel filter
replacement."
10. For vehicles with automatic transaxles, disconnect transaxle oil cooler hoses.
When disconnecting the hoses, make identification marks to avoid making mistakes when reconnecting
them.
Be caurful not to spill oil or fluid from hoses, plug the openings to prevent foreign material from entering.
Page 23 of 98
11. Drain the engine coolant from the radiator.
12. Disconnect the radiator upper and lower hoses on the engine side, then remove the radiator assembly.
13. Disconnect the heater hoses (inlet and outlet) on the engine side.
14. Disconnect the accelerator cable at the engine side.

15. For vehicles with 5-speed manual transaxles, remove the clutch release cylinder.
16. For vehicles with manual transaxles, remove the shift control cable from the transaxle.
Page 24 of 98
17. For vehicles with automatic transaxles, remove the control cable from the transaxle.
18. Disconnect the speedometer cable from the transaxle.
19. Disconnect the air conditioning compressor from the mounting bracket.
20. Disconnect the starter motor connector and ground.
Page 25 of 98
21. Remove the steering dust cover, the U-joint bolt and the gear box assembly.
Mark between U-joint and gear box before disassembling.
22. Jack up the vehicle and remove the front tire.

23. Remove the caliper assembly from knuckle and hold the upper side.
24. Loosen the strut lower bolt and separate from the knuckle.
25. Remove the wheel speed sensor from the knuckle. (with ABS)
Page 26 of 98
26. Disconnect the front exhaust pipe from the manifold.
Use wire to suspend the exhaust pipe from the bottom of the
vehicle.
27. Attach chains or cables to the engine.
Use an engine hoist or a chain hoist to slightly raise the engine (enough to support the engine's wieght while
continning with the following steps.)
28. Remove the engine mounting bracket from the engine.
29. Slowly raise the engine (to the extent that the weight of the engine and transmission assembly is not applied to
the mounting portions) and temporarily hold it in the raised position.
Page 27 of 98
30. Remove the caps from the inside of the right fender shield and remove the transaxle mount bracket bolts.
31. Remove the cross member fixing bolts and nuts.
32. While directing the transmission side downward, lift the engine and transmission assembly down and out of the
vehicles.
Engine Mechanical System > Timing System > Timing Belt > Components and Components Location
COMPONENTS
Page 28 of 98
Engine Mechanical System > Timing System > Timing Belt > Repair procedures
DISAESSEMBLY
Page 29 of 98
1. Loosen the coolant pump pulley bolts.
2. Loosen the alternator bolt.

3. Remove the coolant pump pulley and belt.
4. Remove the crankshaft pulley.
5. Remove the timing belt cover.
6. Align the timing marks of the camshaft sprocket and crankshaft sprocket, with the No.1 piston placed at top
dead center on its compression stroke.
Page 30 of 98
7. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it.
8. Remove the timing belt.
9. Remove the camshaft sprocket.

10. Remove the crankshaft sprocket bolts. Remove the crankshaft sprocket and flange.
11. Remove the timing belt tensioner.
INSPECTION
TIMING BELT
1. Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry
cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, carefully check the belt. If any of the following flaws are
evident, replace the belt.
Description Flaw conditions
1. Hardened back surface
Back surface glossy. Non-elastic and so hard that when your
fingernail is pressed into it, no mark is produced.
2. Cracked back surface rubber
3. Cracked or separating canvas

Page 31 of 98
4. Badly worn teeth (initial stage)

Canvas on load side tooth flank worn (Fluffy canvas fibers, rubber
gone and color changed to white, and unclear canvas texture)
5. Badly worn teeth (last stage)

Canvas on load side tooth flank worn down and rubber exposed
(tooth width reduced)
6. Cracked tooth bottom
7. Missing tooth
8. Side of belt badly worn
A normal belt should have precisely cut sides as if cut by a

sharp knife.
9. Side of belt cracked
SPROCKETS AND TENSIONER

1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks,
or damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth pulley rotation, play or noise. Replace as
necessary.
REASSEMBLY
Page 32 of 98
1. Install the flange and crankshaft sprocket as shown.
Pay close attention to their mounting directions.
Tightening torque
Crankshaft sprocket bolt :
140 ~150Nm (1400 ~ 1500kg.cm, 103 ~ 111lb.ft)
2. Install the camshaft sprocket and tighten the bolt to the specified torque.
Tightening torque
Camshaft sprocket bolt :
80 ~ 100 Nm (800 ~ 1000 kg.cm, 59 ~ 74 lb.ft)
3. Align the timing marks of the camshaft sprocket and crank shaft sprocket, with the No.1 piston placed at top
dead center on its compression stroke.
When installing camshaft sprocket.

Make sure that cmashaft sprocket knock pin fits small hole in pulley as shown.
Page 33 of 98
4. Tentatively fasten the timing belt tensioner where its pulley is nearest the water pump body.
5. Hang the tensioner spring on the tensioner bracket and insert the other side into the front case using a screw
driver.
6. Install the timing belt tightly in the sequence shown.

Crankshaft sprocket → Camshaft sprocket → Timing belt tensioner.
7. Install timing belt so as not to give salck to tension side.
Then make sure that timing marks are at correct position respectively with tension side in strained state by
applying force to camshaft sprocket in reversing direction.
Page 34 of 98
8. Loosen the tensioner mounting bolt in the order as shown to give the timing belt spring tension.
9. Rotate crankshaft in regular direction (clockwise view from front) through angle equivalent to two teeth (15°) of
camshaft sprocket.
10. Add force to tensioner in direction of regular rotation (→ direction) to bring belt teeth in perfect contact with
sprocket teeth without a gap.
11. After making sure of this state.
Fix tensioner so that only the tensioner spring is movable.
12. Rotate the crankshaft pulley two or four turns conter clockwise so that the timing belt positions itselt on the
sprockets.
13. Recheck the belt tension. Verify that when the tensioner and the tension side of the timing belt are pushed in
horizontally with a moderate force [approx. 49N (11 lb)], the timing belt is half of the tensioner mounting bolt
head radius away from the bolt head center.

15. Install the crankshaft pulley.
16. Install the A/C compressor belt and adjust the belt tension.
17. Install the coolant pump pulley.
18. Install the V-belt and adjust the belt tension.
Engine Mechanical System > Cylinder Head Assembly > Camshaft > Components and Components
Location
COMPONENTS
Page 35 of 98
Engine Mechanical System > Cylinder Head Assembly > Camshaft > Repair procedures
DISASSEMBLY
1. Disconnect the breather hose and the PCV hose.
Page 36 of 98
2. Remove the coolant pump pulley and crankshaft pulley.
5. Remove the timing belt from the camshaft sprocket.
6. Remove the camshaft sprocket.
7. Remove the rocker cover.
8. Remove the rocker arm shaft assembly, Refer to "Rocker Arms and Rocker Arm Shafts" section.
9. Remove the camshaft bearing caps.

Page 37 of 98
10. Remove the camshaft.
INSPECTION
CAMSHAFT
1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or worn excessively, replace the camshaft.
Cam height
Standard value
Intake : 42.8575 mm (1.6873 in.)
Exhaust : 42.7354 mm (1.6825 in.)
Limit
Intake : 42.3575 mm (1.6676 in.)
Exhaust : 42.2353 mm (1.6628 in.)
3. Check the cam surface for abnormal wear or damage, and replace if necessary.
4. Check each bearing for damage. If the bearing surface is excessively damaged, Replace the cylinder head
assembly or camshaft bearing cap, as necessary.
OIL SEAL (CAMSHAFT FRONT)
1. Check the lips for wear. If lip threads are worn, replace.
2. Check the oil seal lip contacting surface of the camshaft. If it is worn in stages, replace the camshaft.
Camshaft end play :

0.07 ~ 0.28 mm (0.0003 ~ 0.0011 in.)
REASSEMBLY
1. Install the camshaft after lubricating the journal of the camshaft with engine oil.
2. Install the camshaft bearing caps.
3. Install the rocker arm and rocker arm shaft.
Refer to the "Rocker Arms and Rocker Arm Shafts" section.
Page 38 of 98
4. Using the Special Tools, Camshaft Oil Seal Installer (09221-21000), press and fit the camshaft oil seal. Be sure
to apply engine oil to the external surface of the oil seal.
Insert the oil seal along the camshaft front end and install by driving the installer with a hammer until the oil seal is
fully seated.
5. Install the camshaft sprocket and tighten the bolts to the specified torque.
Tightening torque
Camshaft sprocket bolt :
80 ~ 100 Nm (800 ~ 1000 kg.cm, 59 ~ 74 lb.ft)
6. Align the camshaft sprocket and crankshaft sprocket timing marks. The piston in the No. 1 cylinder will then be
at top dead center on the compression stroke.
7. Intsall a gasket in the rocker cover groove.

8. Temporarily install the rocker cover.
9. Start the engine and run at idle.
10. Install the rocker cover and tighten the bolts to the specified torque.
Tightening torque
Rocker cover bolt : 8~10Nm (80~100 kg.cm, 6~7 lb.ft)

12. Install the coolant pump pulley and crankshaft pulley.
Page 39 of 98
Engine Mechanical System > Cylinder Head Assembly > Valve > Components and Components
Location
COMPONENTS
Engine Mechanical System > Cylinder Head Assembly > Valve > Repair procedures
DISASSEMBLY
Page 40 of 98
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose. (between the air cleaner and the rocker cover)
3. Remove the air intake hose.

4. Remove the vacuum hose, fuel hose and coolant hose.
5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
6. Remove the ignition coil.
7. Remove the surge tank bracket.

Page 41 of 98
8. Remove the intake manifold.
9. Remove the heat protector and exhaust manifold assembly.
10. Remove the coolant pump pulley and the crankshaft pulley.
13. Remove the timing belt.
15. Remove the cylinder head assembly. The cylinder head bolts should be removed using Cylinder Head Bolt
Wrench, in the sequence as shown in the illustration.
16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface.
Make sure that the gasket pieces do not fall in to the engine.
INSPECTION
1. Check the cylinder head for cracks, damage and coolant leakage.
2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed
air to make certain that the passages are not clogged.
Page 42 of 98
3. Check the cylinder head surface for flatness using a straight edge in the direction of A, B, ...as shown.
If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head
surface.
Cylinder head flatness

Standard value : Less than 0.03 mm (0.012 in.)
Limit : 0.08 mm (0.0031 in.)
REASSEMBLY
1. Clean all gasket surfaces of the cylinder block and the cylinder head.
2. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not
reuse the old cylinder head gasket.
3. Install the cylinder head bolts. Starting at top center. Tighten all cylinder head bolts in sequence as shown in
illustration, using the Cylinder Head Bolt Wrench. Repeat the procedure, retightening all cylinder head bolt to the
specified torque.
Tightening torque
23~27Nm (230~270kg.cm, 17~20lb.ft)+60°+60°
5. Install the timing belt on the camshaft sprocket, making sure that the tension side is tightened by turning the
camshaft sprocket in reverse. Make sure all timing marks are in alignment.
6. Adjust the timing according to the "Timing Belt" section.
Page 43 of 98
Tightening torque
Rocker cover bolt :
8 ~ 10 Nm (80 ~ 100 kg.cm, 6 ~ 7 lb.ft)

9. Install the new intake manifold gasket and the intake manifold. Tighten the nuts and bolts to the specified torque.
Tightening torque
Manifold nuts and bolts (both intake and exhaust) :
15 ~ 20 Nm (150 ~ 200 kg.cm, 11 ~ 15 lb.ft)
10. Install the new exhaust manifold gasket and the exhaust manifold. Tighten the exhaust manifold attaching nuts to
the specified torque.
11. Install the surge tank and tighten the nuts and bolts to the specified torque.
Tightening torque
Surge tank to inlet manifold nuts and bolts :
15 ~ 20 Nm (250 ~ 200 kg.cm, 11 ~ 15 lb.ft)
12. Install the ignition coil.

13. Install the air intake hose.
14. Connect the vacuum hose, fuel hose and coolant hose.
15. Install breather hose.
Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Components and
Components Location
COMPONENTS
Page 44 of 98
Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Repair procedures
DISASSEMBLY
1. Using the special tool, valve spring remover and installer, remove the retainer lock. Next, remove the spring
retainer, vlave spring, spring seat and valve.
Keep these parts in order so that they can be rein-stalled in their original positions.
Page 45 of 98
2. Remove the valve stem seals with pliers, and discard them.
Do not reuse the valve stem seals.
INSPECTION
VALVE SPRING
1. Check the valve spring free length and tension. If they exceed the service limit, replace the spring.
2. Using a square, test the squareness of each spring.
If a spring is excessively out of square, replace it.
VALVE SPRING
Standard vlaue
Free height : 42.03 mm (1.655 in.)
Load : 24.7 kg at 34.5 mm
Out of square : 1.5° or less
VALVE GUIDES
Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the vlave guide with the
next oversize part.
VALVE STEM-TO-GUIDE CLEARANCE
Standard vlaue
Intake : 0.030 ~ 0.060 mm (0.0012 ~ 0.0024 in.)
Exhaust : 0.035 ~ 0.065 mm (0.0014 ~ 0.0026 in.)
VALVE GUIDE OVERSIZES

Cylinder head hole size
Size mm (in.) Size mark
mm (in.)
11.05 ~ 11.068 (0.435 ~
0.05 (0.002) O.S. 5
0.4357)
11.25 ~ 11.268 (0.4429
0.25 (0.010) O.S. 25
~ 0.4436)
11.50 ~ 11.518 (0.4528
0.50 (0.020) O.S. 50
~ 0.4534)
VALVE GUIDE REPLACEMENT PROCEDURES

The valve guide is installed using a press fit. Using Value Guide installer (09221- 3F100 A/B) or suitable tool,
Page 46 of 98
replace the valve guide described in the following procedure.
1. Using the valve guide installer push rod, push the valve guide out toward the cylinder block with a press.
2. Machine the valve guide insert hole in the cylinder head to the specified oversize of the new valve guide.
3. Using the valve guide installer or suitable tool, press fit the valve guide. Using the vlalve guide installer makes it
possinle to press fit the valve guide to a predetermined height. Install the vlave guide from the top of the cylinder
head. Note that intake and exhaust valve guides differ in length.
4. After installing the valve guides, insert new valves and check the clearance.
5. Whenever valve guides are replaced, check for valve-to-seat contact, and recondition the valve seats as
necessary.
VALVE SEAT INSERT
Page 47 of 98
VALVE SEAT INSERT REPLACEMENT PROCEDURE

1. Any valve seat insert that has been worn over the service limit should be removed at normal temperature after
cutting away most of the insert wall, using valve seat cutters, as shown in Fig A.
2. After removing the seat insert, machine the seat insert bore using a reamer or a cutter. Cut to the size shown in
the table.
3. Heat the cylinder head to about 250°C (480°F) and press in the oversize seat insert. The oversize seat insert
should be at normal room temperature for installation. After installing a new valve seat insert, resurface the valve
seat using the same procedure described in the first paragraph of "Valve Seat Insert" (above).
VALVE SEAT INSERT OVERSIZES

Size Seat insett height H mm
Description Size mm (in.) Cylinder head I.D. mm (in.)
mark (in.)
0.3 (0.012)
30 5.1~5.3 (0.201~0.2069) 28.80~28.821(1.134~1.135)
Intake valve O.S.
seat insert 0.6(0.024)
60 5.4~5.6 (0.213~0.220) 29.10~29.121(1.146~1.147)
O.S.
0.3 (0.012)
30 5.9~6.1 (0.232~0.240) 34.30~34.325(1.350~1.351)
Exhaust valve O.S.
seat insert 0.6 (0.024)
60 6.2~6.4(0.244~0.252) 34.60~34.625(1.362~1.363)
O.S.
VALVES
Check each valve for wear, damage and distortion of head and stem (B). Repair or correct, if necessary. If stem
Page 48 of 98
end (A) is pitted or worn, resurface. This correction must be limited to a minimum. Also, resurface the valve face.
MARGIN
Standard value
Intake : 1.1 mm (0.043 in.)
Exhaust : 1.4 mm (0.055 in.)
Limit
Intake : 0.8 mm (0.031 in.)
Exhaust : 1.1 mm (0.043 in.)
REASSEMBLY
1. Thoughly clean each part before assembly.

2. Apply engine oil to sliding and rotating parts.
1. After installing the spring seat, fit the stem seal into the valve guide.
To install, fit the seal in by lightly tapping the Special Tool, Valve Stem Oil Seal Installer.
The seal is installed in the specified position by means of the special tool. Incorrect installation of the seal will
adversely affect the lip I.D. and eccentricity, resulting in oil leaking down the valve guides. Therefore, when
installing, be careful not to twist the seal. Do not reuse old stem seals.
2. Apply engine oil to each valve. Insert the valves into the valve guides. Avoid using force when inserting the valve
into the seal. After insertion, check to see if the valve moves smoothly.
Page 49 of 98
3. Install springs and spring retainers. Valve springs should be installed with the enamel coated side toward the valve
spring retainer.
Valve springs should be installed with the enamel coated side toward the valve spring retainer.
4. Using special tool, valve spring remover and installer, compress the spring. Be careful that the valve stem seal is
not distorted by the bottom of the retainer. Then install the retainer locks. After installation of the valves, make
certain that the retainer locks are properly installed.
5. Install the cylinder head. Refer to "Cylinder Head".
Engine Mechanical System > Cylinder Head Assembly > Rocker Arm > Components and Components
Location
COMPONENTS
Page 50 of 98
Engine Mechanical System > Cylinder Head Assembly > Rocker Arm > Repair procedures
DISASSEMBLY
1. Remove the breather hose and PCV valve.

4. Loosen the flange bolts and remove the rocker arm shaft, rocker arms and rocker arm shaft springs as an
assembly.
5. Remove the bolts, the rocker arms and arm shaft springs from the rocker arm shaft.
INSPECTION
ROCKER ARM
1. Check the rocker face.
Replace it damaged or pressed.
Page 51 of 98
2. Check the contact surface on the cam and valve stem.
If badly worn or damaged, replace it.
3. Check the hydraulic lash adjuster (HLA) face that contact the valve stem. If badly worn or damaged, replace the
HLA.
ROCKER ARM SHAFT

1. Check the rocker arm shafts for damage. Replace as necessary.
2. Check the oil hole for any restriction.
Problem Possible cause Action

• Temporary noise on starting a cold Normal This noise will disappear after the oil
engine in the engine has reached normal
pressure.
• Continuous noise when engine is Oil drain out of the high pressure Noise will disappear within 15 minutes
started after longer than 48 hours chamber on HLA, allowing air of engine running at 2000~3000 rpm
parking. to get in. If not refer to item 7 below
• Continuous noise when engine is Insuffecient oil in cylinder head
first started after rebuilding oil gallery.
cylinder head.
• Continuous noise when engine is Oil drain out of the high-
after excessive craking the engine pressure chamber in HLA,
by starter motor or band. allowing air to get in.
• Continuous noise after changing Do not run engine at a speed higher
HLA. than 3000 rpm as this may damage
HLA.
Page 52 of 98
• Continuous noise during idle after Engine oil level too high or too Check oil level.
high speed running. low. Drain or add oil as necessary.
Execssive amount of air in the oil
Check oil supply system
at high engine speed.
Deteriorated oil Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
• Noise cotinues more than 15 Check oil pressure and oil supply
Low oil pressure
minutes. system of each part of engine.
Faulty HLA. Remove the cylinder head over and
press down HLA by band.
If it moves, replace HLA.
Be careful of hot HLA.
HLA roise could occur to your engine due to malfunction of HLA if you use additives besides engine oil
regulated to HMC.
REASSEMBLY
1. Install the rocker arms and rocker arm shaft springs to the rocker arm shafts, install the rocker arm shaft to the
cylinder head.
Tighten the rocker arm shaft mounting bolts to the specified torque.
Tightening torque
Rocker arm shaft mounting bolt :
20 ~ 27 Nm (200 ~ 270 kg.cm, 15 ~ 20 lb.ft)
2. When installing the rocker arm, shaft and spring, mark the difference between left and right parts.
Use the springs without distinction of intake and exhaust valve.
Must set the parts that have smaller chamfers between rocker arm shafts.
Page 53 of 98
Tightening torque
Rockr cover bolt :
8 ~ 10 Nm (80 ~ 100 kg.cm, 6 ~ 7 lb.ft)
1. Sealant must be applied to the top surface of cylinder head and cam caps. Area of application is shown
in figure.
2. The proper amount of sealant must be used to prevent the sealant from squeezing out the sides..
3. Use sealant of specified brands or equivalant.
4. Sealant (Three bond No. 1212D aluminum color or equivalent).
Tightening torque
Timing belt cover bolt :
10 ~ 12 Nm (100 ~ 120 kg.cm, 7 ~ 9 lb.ft)
5. Install the breather hose, PCV hose, blow by hose and spark plug cable.
6. Install the air intake hose and air duct.
Engine Mechanical System > Cylinder Block > Piston and Connecting Rod > Components and
Components Location
COMPONENTS
Page 54 of 98
Engine Mechanical System > Cylinder Block > Piston and Connecting Rod > Repair procedures
DISASSEMBLY
1. Use the Special Tools to disassemble and reassemble the piston and connecting rod.
2. Place the proper fork inserts in the fork of the tool.

Between the connecting rod and the piston.
3. Insert the proper removal tool through the hole in the arch of the tool.
Center the piston, rod and pin assembly with the removal arbor.
Page 55 of 98
4. Press the piston pin out of the connecting rod.
INSPECTION
PISTON AND PISTON PINS
1. Check each piston for scuffing, scoring wear, and other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the piston
requires replacement, also replace the rings.
3. Check the piston pin fit in the piston pin hole. Replace any defective piston and pin assembly that is defective.
The piston pin must be smoothly pressed by hand into the pin hole (at room temperature).
PISTON RINGS
1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in a ring
groove to measure the side clearance. If the clearance still exceeds the service limit, replace the piston and rings
together. If it is less than the service limit, replace only the piston rings.
Piston ring side clearance

Standard value
No. 1 : 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.)
No.2 : 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.)
Limit
No. 1 : 0.1 mm (0.004 in.)
No. 2 : 0.1 mm (0.004 in.)
2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston ring.
Item Standard - mm (in.) Limit - mm (in.)
Piston ring end gap No.1 0.20 ~ 0.35 (0.0079 ~ 0.0138) 1 (0.039)
Piston ring end gap No.2 0.37 ~ 0.52 (0.015 ~ 0.02) 1 (0.039)
Oil ring side rail end gap 0.20 ~ 0.70 (0.0078 ~ 0.0275) 1 (0.039)
When replacing the ring without correcting the cylinder bore, check the gap with the ring positioned at the bottom
of the ring travel.
When replacing a ring, use a ring of the same size.
Piston ring service size and mark

STD : None
0.25 mm (0.010 in.) O.S. : 25
0.50 mm (0.020 in.) O.S. : 50
Page 56 of 98
The mark can be found on the upper side of the ring.
REASSEMBLY
1. Install the spacer.
2. Install upper side rail. To install side rail, first put one end of side rail between piston ring groove and spacer, hold
it down firmly, then press down the portion to be inserted with your finger into groove as illustrated.
Do not use piston ring expander when installing side rail.

3. Install lower side rail using same procedure as Step 2.
4. Using piston ring expander, install No. 2 piston ring.
5. Install No. 1 piston ring.
6. Apply engine oil around piston and piston rings.

7. Position each piston ring end gap as far apart from neighboring gaps as possible. Make sure that gaps are not
positioned in side rail thrust and pin directions.
Page 57 of 98
8. Hold piston rings firmly in a piston ring compressor as you insert them into cylinder.
9. Make sure that the front mark of piston and the front mark (identification mark) of connecting rod are directed
toward frront of engine.
10. When connecting rod cap is installed, make sure that cylinder numbers put on rod and cap at disassembly match
each other.
11. When new connecting rod is installed, make sure that notches for holding bearing in place are on same side.
12. Tighten the connecting rod cap nuts.
Tightening torque
Connecting rod cap nuts
32 ~ 35 Nm (320 ~ 350 kg.cm, 24 ~ 26 lb.ft)
13. Check connecting rod side clearance.
Connecting rod side clearance

Standard value : 0.10 ~ 0.25 mm (0.004 ~ 0.0098 in.)
Limit : 0.4 mm (0.0157 in.)
REPLACEMENT
Page 58 of 98
1. Check the cylinder bore size code on the cylinder block top face.
Class Cylinder bore inner diameter Size code

75.5 ~ 75.51 mm
A A
(2.9724 ~ 2.9728 in.)
75.51 ~ 75.52 mm
B None
(2.9728 ~ 2.9732 in.)
75.52 ~ 75.53 mm
C C
(2.9732 ~ 2.9736 in.)
2. Check the piston size code on the piston top face.
Size
Class Piston outer diameter
code
75.47 ~ 75.48 mm
A A
(2.9712 ~ 2.9716 in.)
75.48 ~ 75.49 mm
B None
(2.9716 ~ 2.9720 in.)
75.49 ~ 75.50 mm
C C
(2.9720 ~ 2.9724 in.)
3. Selece the piston related to cylinder bore class.
Oil clearance : 0.02 ~ 0.04 mm (0.00078 ~ 0.00157 in.)
INSTALLATION
Page 59 of 98
1. Install proper pin guide through piston and into connecting rod. Hand tap pin guide into piston for proper
retention. Drop piston pin into the other side of the piston.
The pin guide centers the connecting rod in the piston. When the piston, connecting rod, piston pin and pin
guide assembly are positioned on the fork of the tool, the pin guide will also center this assembly in the
tool.If too small a pin guide is used, the piston assembly will not be located centrally in the tool, and
damage may occur to the fork and/or insert of the tool.
2. Install piston assembly onto fork assembly of tool.

Tool will support connecting rod at the piston pin. Be sure to slide the piston assembly into the fork until the pin
guide contacts the fork insert.
3. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the
specified alpha-numeric setting from the application chart is obtained. Turn knurled nut to lock numbered sleeve
on shaft.
4. Insert the installing arbor through the hole in the arch of the tool. Press the piston pin into the connecting rod until
the sleeve on the installing arbor contacts the top of the tool arch. The pin guide will fall out of the connecting rod
as the piston pin is pressed in.
Do not exceed 5000 pounds of force when stopping the installing arbor sleeve against the arch.
Engine Mechanical System > Cylinder Block > Crankshaft > Components and Components Location
COMPONENTS
Page 60 of 98
COMPONENTS
Page 61 of 98
Engine Mechanical System > Cylinder Block > Crankshaft > Repair procedures
DISASSEMBLY
1. Remove the transaxle and clutch.
2. Remove the flywheel.
DISASSEMBLY
1. Remove the timing belt train, front case, flywheel cylinder head assembly and oil pan. For details, refer to related
chapters.
2. Remove the rear plate and the rear oil seal.
Page 62 of 98
3. Remove the connecting rod caps.
4. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order according to the cap
number.
5. Remove the crankshaft position sensor wheel.
Mark the main bearing caps to permit reassembly in the original position and
direction.
INSPECTION
1. Check the clutch disc contacting surface of the fly wheel for damage and wear. Replace the flywheel if
excessively damaged or worn.
2. Check the clutch disc contacting surface of the fly wheel for runout.
Standard value
Flywheel run-out : 0.1 mm (0.004 in.)
3. Check the ring gear for damage, crack and wear, and replace if necessary.
INSPECTION
CRANKSHAFT
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check oil holes for clogging.
Correct or replace any defective part.
2. Inspect out-of-roundness and taper of crankshaft journal and pin.
Standard value
Crankshaft journal O.D. : 50 mm (1.9685 in.)
Crankshaft pin O.D. : 45 mm (1.7717 in.)
Crankshaft journal, pin out-of-roundness and taper :
0.01 mm (0.0004 in.) or less
MAIN BEARINGS AND CONNECTING ROD BEARINGS

OIL CLEARANCE MEASUREMENT
Standard value
Journal oil clearance No. 1, 2, 4, 5 :
0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in.)
Journal oil clearance No. 3 (center) :
0.028 ~ 0.046 mm (0.0011 ~ 0.0018 in.)
Pin oil clearance :
0.018 ~ 0.036 mm (0.0007 ~ 0.0014 in.)
PLASTIC GAUGE METHOD

1. Remove oil, grease and any other dirt from bearings and journals.
Page 63 of 98
2. Cut plastic gauge to the same length as the width of the bearing and place it parallel with the journal, away from
the oil holes.
3. Install the crankshaft , bearings, and caps. Tighten them to the specified torque. During this operation, do not turn
the crankshaft. Remove the caps.
Measure the width of the plastic gauge at the widest point using the scale printed on the gauge package.
If the clearance exceeds the repair limit, replace the bearing.
Should the standard clearance not be obtained even after bearing replacement, the journal should be machined to
a recommended undersize, and a bearing of the same size should be installed.
OIL SEAL
CRANKSHAFT POSITION SENSOR WHEEL
1. Remove the crankshaft position sensor wheel.
2. Check the crankshaft position sensor wheel for damage, cracks and wear. Replace if necessary.
3. Check the clearance between the crankshaft position sensor wheel and the crankshaft position sensor with a
depth gage.
Standard value
Clearance between the crankshaft position sensor wheel and crankshaft position sensor :
0.5 ~ 1.5 mm (0.020 ~ 0.059 in.)
Page 64 of 98
1. Measure the depth of the top of the crankshaft position sensor wheel teeth and the outside of transaxle
housing.
2. Measure the difference between the crankshaft position sensor length and depth.
3. The crankshaft position sensor length is the distance between the end of crankshaft position sensor and
inner point of contacting face.
REASSEMBLY
Install the flywheel assembly and tighten the bolts to the specified forque.
Tightening torque
Flywheel bolt :
130 ~ 140 Nm (1300 ~ 1400 kg.cm, 96 ~ 103 lb.ft)
REASSEMBLY
1. Install the upper main bearing inserts in the cylinder block.
2. Install the crankshaft. Apply engine oil to the journals.
3. Install bearing caps and tighten cap bolts to the specified torque in the sequence of the center, No.2, 4, front and
rear caps.
Cap bolts should should be tightened evenly in 2 to 3 stages before they are tightened to the specified torque.
The caps should be installed with the arrow mark directed toward the crank pulley side of engine. Cap numbers
must be correct.
Tightening torque
Main bearing cap bolt :
55 ~ 60 Nm (550 ~ 600 kg.cm, 41 ~ 44 lb.ft)
Connecting rod cap bolt :
32 ~ 35 Nm (320 ~ 350 kg.cm, 24 ~ 26 lb.ft)
Page 65 of 98
4. Make certain that the crankshaft turns freely and has the proper clearance between the center main bearing thrust
flange and the connecting rod big end bearing.
Standard value
Crankshaft end play :
0.05 ~ 0.175 mm (0.002 ~ 0.005 in.)
5. Install the oil seal in the crankshaft rear oil seal case.
Use the special tool, crankshaft rear oil seal installer (09231 - 21000) as shown. Press and fit the oil seal in all the
way, being careful not to misalign it.
6. Install the rear oil seal case and gasket. Tighten the five bolts.
Apply engine oil to the oil seal lips and crankshaft at the time of installation.
7. Install the rear plate and tighten the bolts.
8. Install the connecting rod caps. Refer to the "Piston and Connecting Rods" section.
9. Install the flywheel, front case, oil pan and timing belt.
For further details, refer to the respective chapters.
REPLACEMENT
Page 66 of 98
1. Check the cylinder block stamping crankshaft bore size code.
Record the cylinder block crankshaft bore size code letters on cylinder block as
shown.
Reading order is from left to right with front crankshaft bore size code shown first.
Cylinder block crankshaft bore diameter
Class Cylinder block crankshaft bore diameter Size code.
54 ~ 54.006 mm
a Λ
(2.1259 ~ 2.1262 in.)
b 54.006 ~ 54.012 mm (2.1262 ~ 2.1264 in.) b
c 54.012 ~ 54.016 mm (2.1264 ~ 2.1266 in.) c
2. Check the crankshaft main journal
Record the main journal size code letters on the crankshaft blance weight.
Reading order is from left to right as shown, with no.1 main journal size code shown
first.
CRANKSHAFT MAIN JOURNAL DIAMETER

Class Main journal diameter Size code.
49.968 ~ 49.962 mm
I Λ
(1.9672 ~ 1.9670 in.)
49.962 ~ 49.956 mm
II b
(1.9670 ~ 1.9667 in.)
49.956 ~ 49.950 mm
III c
(1.9667 ~ 1.9665 in.)
Page 67 of 98
MAIN JOURNAL BEARING THICKNESS
No. 1, 2, 4, 5
Color Main journal bearing thickness
Yellow 2.002~2.005mm (0.0788~0.0789in.)
Green 2.005~2.008mm (0.0789~0.0790in.)
No color 2.008~2.011mm (0.0790~0.0791in.)
Black 2.011~2.014mm (0.0791~0.0793in.)
Blue 2.014~2.017mm (0.0793~0.0794in.)
No.3 (Center bearing)

Color Main journal bearing thickness
Yellow 1.999~2.002mm (0.0787~0.0788in.)
Green 2.002~2.005mm (0.0788~0.0789in.)
No color 2.005~2.008mm (0.0789~0.0790in.)
Black 2.008~2.011mm (0.0790~0.0791in.)
Blue 2.011~2.014mm (0.0791~0.0793in.)
3. Choose proper main journal bearing in table.
Engine Mechanical System > Cylinder Block > Cylinder Block > Components and Components
Location
COMPONENTS
Page 68 of 98
Engine Mechanical System > Cylinder Block > Cylinder Block > Repair procedures
INSPECTION
CYLINDER BLOCK
1. Visually check the engine block for scores, rust and corrosion. Also check for cracks or any other defects.
Repair or replace the block if defective.
Page 69 of 98
2. Using a straight edge and feeler gauge, check the block top surface for warpage. Make sure that the surface is
free from gasket chips and other foreign matter.
Standard : 0.05 mm (0.0020 in.) or less

Limit : 0.1 mm (0.0039 in.)
3. Measure the cylinder bore with a cylinder gauge at three levels in the directions A and B. If the cylinder bores
show more than the specified out-of-round-ness or taper or if the cylinder walls are badly scuffed or scored, the
cylinder block should be rebored and honed. New oversize pistons and rings must be fitted. Measuring points are
as shown.
Cylinder I.D. : 75.5 mm (2.9724 in.)

Cylinder I.D. taper : 0.02 mm (0.0008 in,.) or less
4. If a cylinder ridge exists, cut away with a ridge reamer.

5. Oversize pistons are available in four sizes
Piston service size and mark mm (in.)

0.25 (0.010) O.S. : 25
0.50 (0.020) O.S. : 50
6. When boring the cylinder bore to oversize, keep the specified clearance between the oversize piston and the
bore. Make sure that all pistons used are of the same oversize.
Piston - to - cylinder wall clearance :

0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)
Engine Mechanical System > Cylinder Block > Engine Mounts > Components and Components
Location
COMPONENTS
Page 70 of 98
Engine Mechanical System > Cylinder Block > Engine Mounts > Repair procedures
REMOVAL
Page 71 of 98
1. Remove the front roll stopper bracket from the sub-frame. (14 mm bolt and nut, 17 mm bolt.)
2. Remove the rear roll stopper bracket from the sub-frame.
3. Engine
(1) Remove the engine mount bracket from the engine. (14 mm, 17 mm)
(2) Remove the engine mount insulator.
Page 72 of 98
4. Transaxle
(1) Remove the transaxle mount bolt. (17 mm)
(2) Detach the cap from inside the right fender shield. Remove the transaxle mount bolts.
(3) Remove the transaxle mount bracket.
Engine Mechanical System > Cooling System > Water pump > Components and Components Location
COMPONENTS
Page 73 of 98
Engine Mechanical System > Cooling System > Water pump > Repair procedures
DISASSEMBLY
1. Drain the coolant and disconnect the coolant outlet pipe connection hose from the coolant pump.
2. Remove the drive belt and engine coolant pump pulley.
3. Remove the timing belt covers and the timing belt idler.
4. Remove the coolant pump mounting bolts, then remove the generator brace.
5. Remove the coolant pump assembly from the cylinder block.
INSPECTION
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation. Replace the coolant pump assembly if
necessary.
Page 74 of 98
3. Check for coolant leakage. If coolant leaks form hole "A", the seal is defective. Replace the coolant pump
assembly.
REASSDEMBLY
1. Clean the gasket surfaces of the coolant pump body and the cylinder block.
2. Install a new coolant pump gasket to the coolant pump and tighten the bolts to the specified torque.
Tightening torque
Coolant pump bolt to cylinder block :
12 ~ 15 Nm (120 ~ 150 kg.cm, 9 ~ 11 lb.ft)
3. Install the timing belt idler and timing belt. Adjust the timing belt tension. Refer to the "Timing System" section.
4. Install the timing belt covers.
5. Install the coolant pump pulley, drive belt and adjust the belt tension.
6. Refill the system with clean coolant.
7. Run the engine and check for leaks.
Engine Mechanical System > Cooling System > Thermostat > Components and Components Location
COMPONENTS
Page 75 of 98
Engine Mechanical System > Cooling System > Thermostat > Repair procedures
INSPECTION
1. Drain the coolant down to thermostat level or below.
2. Remove the coolant outlet fitting and gasket.
3. Remove the thrmostat.
Page 76 of 98
4. Immerse the thermostat in hot coolant to check proper valve opening temperature. Replace if necessary.
Valve opening temperature : 82° C (177° F)

Full opening temperature : 95° C (205 °F)
Valve lift (at full open) : 8.5 mm (0.33 in.) or more
COOLANT TEMPERATURE SENDER

1. Heat the engine coolant temperature sender by submerging it in hot water.
2. Check that the resistance is within the specified range.
Resistance : 123.8 ~ 172.8 Ω at 60°C (140°F)

23.5 ~ 29.5 Ω at 115°C (239°F)
REASSEMBLY
1. Verify the flange of the thermostat is correctly seated in the socket of the thermostat housing. If the thermostat is
installed in the wrong direction, the bottom of the thermostat will thuch the rib inside the intake manifold, making it
impossible for the thermostat to operate properly.
2. Install a new gasket and the coolant outlet fitting.
3. Refill the system with clean coolant.
Engine Mechanical System > Cooling System > Radiator > Repair procedures
DISASSEMBLY
Page 77 of 98
1. Disconnect the radiator fan motor connector.
2. Set the temperature of the heater control to the hot position.

3. Loosen the radiator drain plug to drain coolant.
4. Disconnect the upper and lower hose and overflow tube.

5. For vehicles with automatic transaxles, disconnect the oil cooler hoses from the automatic transaxle.
Plug the ends of the oil cooler hoses and the automatic transaxle fittings to prevent transaxle fluid form
spilling out and foreign material from entering.
6. Remove the radiator mounting bolts.
7. Remove the radiator together with the fan motor.

8. Remove the fan motor from the radiator.
INSPECTION
1. Check the radiator for bent, broken or plugged fins.
Page 78 of 98
2. Check the radiator for corrosion, damage, rust or scale.
3. Check the radiator hoses for cracks, damage or deterioration.
4. Check the reservoir tank for damage.
5. Check the radiator cap spring for damage.
6. Test the pressure of the cap using a cooling system checker
7. Check the radiator cap seal for cracks or damage.
RADIATOR FAN MOTOR
1. Check that the radiator fan rotates when battery voltage is applied to the terminals (as shown in figure).
2. Check that abnormal noises are not produced while the motor is turning.
REASSEMBLY
1. Fill the radiator and reservoir tank with clean coolant mixture.
2. Run the engine until the thermostat opens, and then stop the engine.
3. Remove the radiator cap, and add coolant up to the filler neck of the radiator, and then fill the reservoir tank to
the upper level.
4. Check that there is no leakage from the radiator, hoses or connections.
Engine Mechanical System > Cooling System > Radiator Cap > Components and Components Location
COMPONENTS
Page 79 of 98
Engine Mechanical System > Cooling System > Radiator Cap > Repair procedures
INSPECTION
1. Check the radiator cap for damage, cracks and deterioration.
2. Attach a radiator cap tester to the radiator.

3. Pump the tester until the pointer stabilizes.
4. If the pointer stays constant for 10 seconds at a pioint exceeding the service limit, the radiator cap is good.
Page 80 of 98
Engine Mechanical System > Cooling System > Engine Coolant Hose / Pipes > Components and
Components Location
COMPONENTS
Engine Mechanical System > Cooling System > Engine Coolant Hose / Pipes > Repair procedures
INSPECTION
1. Check the coolant pipes and hoses for cracks, damage, or restrictions.
2. Replace if necessary.
REASSEMBLY
1. Fit the O - ring in the groove provided at the coolant inlet pipe end, wet the O-ring with coolant and insert into
the coolant inlet pipe.
Page 81 of 98
2. Make sure that there is a yellow mark on the inlet coolant hose and while keeping the yellow mark toward of the
coolant inlet pipe, fit the hose to the pipe to the end of the yellow mark.
1. Do not apply oil or grease to the coolant pipe O-ring

2. Keep the coolant pipe connections free of sand, dust, etc.
3. Insert the coolant pipe fully into the coolant pump.
4. Do not reuse the O-ring, replace it with a new one.
Engine Mechanical System > Lubrication System > Oil Pump > Description and Operation
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter.
2. Check the continuity between the terminal and the body when the fine wedge is pushed. If there is continuity enve
when the fine wedgew is pushed, replace it.
3. However, if there is non continuity when a 50 Kpa (70 psi) vacuum is applied through the oil hole, the switch is
operating properly. Check to see that air doesn't leak. If air leaks, the diaphragm is broken. Replace the switch.
Engine Mechanical System > Lubrication System > Oil Pump > Components and Components Location
COMPONENTS
Page 82 of 98
Engine Mechanical System > Lubrication System > Oil Pump > Repair procedures
DISASSEMBLY
1. Remove the timing belt. Refer to the "Timing Belt" section.
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen.
5. Remove the front case assembly.
6. Remove the oil pump cover.
Page 83 of 98
7. Remove the inner and outer gears from the front case. The mating marks on the inner and outer gears indicate the
direction of installation. Make sure that the inner and outer gears are installed as shown.
8. Remove the plug and remove the relief spring and relief plunger.
INSPECTION
OIL PAN AND OIL SCREEN
1. Check the oil pan for failure, damage or cracks. Replace of defective.
2. Check the oil screen for failure, damage and cracks and replace of defective.
FRONT CASE AND OIL PUMP COVER
Check for worn (especially stepped) or damaged surfaces contacting gears.
OIL PUMP GEARS
1. Check for worn or damaged gear teeth surfaces.
2. Check for clearance between outer gear and front case.
Outer gear
Clearance between outer circumference and front case :
0.12 ~ 0.18 mm (0.005 ~ 0.007 in.)
3. Check the tip clearance on the pump rotor.
Standard value :
0.025 ~ 0.069 mm (0.001 ~ 0.003 in.)
Page 84 of 98
4. Check the axial clearance on the outer pump roter.
Standard value :
0.04 ~ 0.087 mm (0.0016 ~ 0.0034 in.)
REASSEMBLY
OIL PUMP
1. Install the outer and inner gears into the front case.
Make sure that the inner and outer gears are installed in the same direction as shown.
2. Install the oil pump cover and tighten the bolts to the specified torque. Atfer the bolts have been tithtened, check
to ensure that the gear turns smoothly.
Tightening torque
Oil pump cover bolt :
8 ~ 12 Nm (80 ~ 120 kg.cm, 6 ~ 8.8 lb.ft)
3. Install the relief valve and spring. Tighten the plug to the specified torque. Apply engine oil to the relief valve.
Tightening torque
Relief valve plug :
40 ~ 50 Nm (400 ~ 500 kg.cm, 30 ~ 37 lb.ft)
Page 85 of 98
OIL SEAL
1. Inspect for worn, distorted or damaged lips.
2. Check for elongated spring ring.
3. Install the Special Tool, Crankshaft Front Oil Seal Guide (09231 - 22100), to the front end of the crankshaft.
Apply engine oil to the outer surface of the oil seal guide, and install the new oil seal along the guide by hand, until
it touches front case. Always use a new oil seal when reassembling.
4. Use the Special Tool, Crankshaft Front Oil Seal Installer (09231 - 22000), to install the oil seal.
5. Install the crankshaft sprocket, timing belt and crankshaft pulley. Refer to the "Timing Belt" section.
6. Install the oil screen.
7. Clean both gasket surfaces of the oil pan and the cylinder bolck.
8. Apply sealant into the groove of the oil pan flange as shown.
1. Apply sealant approx. 4 mm (0.16 in.) in thickness.

2. After application of sealant, do not exceed 15 minutes before installing the oil
pan.
9. Install the oil pan and tighten the bolts to the specified torque.
Tightening torque
Oil pan bolt : 10 ~ 12 Nm (100 ~ 120 kg.cm, 7 ~ 9 lb.ft)
Page 86 of 98
Engine Mechanical System > Intake And Exhaust System > Air Cleaner > Components and
Components Location
COMPONENTS
Engine Mechanical System > Intake And Exhaust System > Air Cleaner > Repair procedures
REMOVAL
1. Remove the air duct connected to the air cleaner.
2. Remove the air intake hose from the air cleaner side.
3. Remove the air cleaner cover and filter.
Page 87 of 98
4. Remove the air cleaner mounting bolts and remove the air cleaner.
INSTALLATION
INSPECTION
1. Check the air cleaner body, cover, and filter for distortion, corrosion or damage.
2. Check the air duct for damage.

3. Check the resonator for distortion or damage.
4. Check the air cleaner filter for restrictions, contamination or damage.
If the filter is slightly restricted, remove dust and other contaminants by blowing air from the upper side through
the filter.
5. Check the air cleaner housing for restrictions, contamination or damage.
Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Components and
Components Location
Page 88 of 98
COMPONENTS
Engine Mechanical System > Intake And Exhaust System > Intake Manifold > Repair procedures
REMOVAL
Page 89 of 98
1. Disconnect the ISA, TPS and MAP sensor.
2. Remove the intake air hose connected to the throttle body.

3. Remove the accelerator cable.
4. Remove the P.C.V. hose and brake booster vacuum hose.
5. Remove the coolant hose connections from the throttle body.
6. Disconnect the fuel injector harness connector.
7. Remove the delivery pipe and fuel injectors from the intake manifold.
Page 90 of 98
8. Remove the surge tank stay.
9. Remove the intake manifold.
INSTALLATION
1. Install the delivery pipe with the fuel injectors attached.
Be careful not to drop the injectors when removing the delivery

pipe.
2. Ensure that insulators are correctly inserted into the delivery pipe hole.
INSPECTION
SURGE TANK
Check the surge tank for defects or cracks.
Replace if necessary.
INTAKE MANIFOLD
Check for damage or cracking of any part.
AIR HOSE
Check for damage or cracking of any part.
Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold > Components and
Components Location
COMPONENTS
Page 91 of 98
Engine Mechanical System > Intake And Exhaust System > Exhaust Manifold > Repair procedures
INSPECTION
EXHAUST MANIFOLD
EXHAUST MANIFOLD GASKET

Page 92 of 98
Engine Mechanical System > Intake And Exhaust System > Muffler > Components and Components
Location
COMPONENTS
Engine Mechanical System > Intake And Exhaust System > Muffler > Repair procedures
Page 93 of 98
REMOVAL
TAIL PIPE
Before removing or inspecting the exhaust system, ensure that it has cooled sufficiently.
1. Disconnect the tail pipe muffler from the center muffler.
2. Remove the rubber hangers and take out the tail pipe.
CENTER PIPE
1. Remove the center muffler assembly from the tail pipe.
2. Remove the rubber hanger, then remove the center muffler.
CATALYTIC CONVERTER
FRONT EXHAUST PIPE
1. Remove the front exhaust pipe from the catalytic converter (unleaded vehicle) or exhaust manifold (leaded
vehicle).
2. Remove the front exhaust pipe clamp bolt and remove the center muffler mounting nut.
INSTALLATION
1. Install the catalytic converter assembly, front exhaust pipe, center exhaust pipe and the tail pipe. In that specific
order.
2. Tighten the parts securely. Make sure there is no interference with any body components.
INSPECTION
1. Check the mufflers and pipes for corrosion and damage.
2. Check the rubber hanger and bands for deterioration and cracks.
Page 94 of 98
Engine Mechanical System > Troubleshooting > P0128

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

DTC Strategy ● Coolant temperature profile check
● Max. coolant temp. – current coolant temp. <
Threshold value
4.5 degC(40.1 °F)
● Ambient temperature (model) 0-45 degC( 32
● Contaminated, deterriorated or
°F~113 °F)
damaged ETCS
● Engine speed > 640 rpm
● Faulty thermostat
● Integrated air mass > 0.5 kg
Enable Conditions ● Foreign materials fouled ETCS
● Coolant temperature at start 0-45 degC( 32
● Faulty ECTS
°F~113 °F)
● Faulty PCM
● Coolant temperature > 97 degC( 206.6 °F)
● Accumulated air mass > limit f(tmst, tum)
Fail Safe
If any codes relating to ECTS, IATS circuits are present,do all repairs associated with those codes before
proceeding with this troubleshooting procedure.
MONITOR DTC STATUS

Page 95 of 98
3. Monitor the "ECTS signal" parameter on the scantool.
If the output data changes as temoerature changes,the sensor is good

If the ECTS output is in inverse proportion to water temperature,the sensor is normal.
Service standard
When ECT is 0°C (32°F) : 4.27 ± 0.3 V
When ECT is 20°C(68°F) : 3.44 ± 0.3 V
When ECT is 40°C(104°F) : 2.72 ± 0.3 V
When ECT is 80°C(176°F) : 1.25 ± 0.3 V

damage.
Repair as necessary and go to "Verification vehicle Repair" procedure.
Go to ""Component Inspection" procedure.
Page 96 of 98
1. Cooling System inspection
(1) Check cooling system coolant level and fill if low.
(2) Check for a proper cooling system operation. Especially check that cooling and condenser fan working
normally.
(3) Remove the thermostat and check the following items:
1) Stuck or damaged Full open lift : 8.5mm(0.33 in) or more
2)Verify the temperature at which the valve begins to open.Initial valve opening temperature : 82°C(179.6°F)
Full valve opening temperature : 95°C(203°F)
(4) Is a problem found?
Repair as necessary and go to "Verification vehicle Repair" procedure
Go to "Check ECTS" as below.

2. Check ECTS
Go to "Check PCM" as below.
Open circuit ECTS .

3. Check PCM
The purpose of checking ECM is to determine whether there is any malfunction of PCM .
(1) Ignition "OFF"
(2) Connect Scantool and Engine "ON "
(3) Select simulation function on scantool.
(4) Simulate voltage at terminal 1 of ECT sensor signal connector.
Page 97 of 98
(5) Verify ECTS voltage to change while raising or lowering simulation voltage with scan tool within 0.5~3.5 V
(6) Is ECT sensor signal value changed according to simulation voltage ?
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or

SCHEMATIC DIAGRAM
Page 98 of 98
Page 1 of 353
ACCENT(LC) > 2005 > G 1.5 SOHC > Fuel System
Fuel System > General Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and name) Illustration Application
09353-24100 Connection of fuel pressure gauge to
Fuel pressure gauge & hose delivery pipe for measurement of fuel
pressure.
09353-38000
Fuel pressure gauge adaptor
09353-24000
Fuel pressure gauge connector
Fuel System > General Information > Description and Operation

INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE
DTC
CONTENT MIL
NO.
P0030 Heated Oxygen Sensor Heater Control Circuit (Bank 1 / Sensor 1) O
P0031 Heated Oxygen Sensor Heater Circuit Low (Bank 1 / Sensor 1) O
P0032 Heated Oxygen Sensor Heater Circuit High (Bank 1 / Sensor 1) O
P0036 Heated Oxygen Sensor Heater Control Circuit (Bank 1 / Sensor 2) O
P0037 Heated Oxygen Sensor Heater Circuit Low (Bank 1 / Sensor 2) O
P0038 Heated Oxygen Sensor Heater Circuit High (Bank 1 / Sensor 2) O
P0106 Manifold Absolute Pressure / Barometric Pressure Circuit Range/Performance O
P0107 Manifold Absolute Pressure / Barometric Pressure Circuit Low Input O
P0108 Manifold Absolute Pressure / Barometric Pressure Circuit High Input O
P0111 Intake Air Temperature Circuit Range / Performance O
P0112 Intake Air Temperature Circuit Low Input O
P0113 Intake Air Temperature Circuit High Input O
P0116 Engine Coolant Temperature Circuit Range / Performance O
P0117 Engine Coolant Temperature Circuit Low Input O
P0118 Engine Coolant Temperature Circuit High Input O
P0121 Throttle Pedal Position Circuit Range / Performance Problem O
Page 2 of 353
P0122 Throttle / Pedal Position Circuit Low Input O
P0123 Throttle / Pedal Position Circuit High Input O
P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control O
P0128 Coolant Thermostat (Coolant Temp. below Thermostat Regulating Temp.) O
P0130 Heated Oxygen Sensor Circuit (Bank 1 / Sensor 1) O
P0131 Heated Oxygen Sensor Circuit Low Voltage (Bank 1 / Sensor 1) O
P0132 Heated Oxygen Sensor Circuit High Voltage (Bank 1 / Sensor 1) O
P0133 Heated Oxygen Sensor Circuit Slow Response (Bank 1 / Sensor 1) O
P0134 Heated Oxygen Sensor Circuit No Activity Detected (Bank 1 / Sensor 1) O
P0136 Heated Oxygen Sensor Circuit (Bank 1 / Sensor 2) O
P0137 Heated Oxygen Sensor Circuit Low Voltage (Bank 1 / Sensor 2) O
P0139 Heated Oxygen Sensor Circuit Slow Response (Bank 1 / Sensor 2) O
P0140 Heated Oxygen Sensor Circuit No Activity Detected (Bank 1 / Sensor 2) O
P0230 Fuel Pump Primaty Circuit X
P0261 Cylinder 1 - Injector Circuit Low O
P0262 Cylinder 1 - Injector Circuit High O
P0300 Random/Multiple Cylinder Misfire Detected O
P0301 Cylinder 1 - Misfire detected O
P0325 Knock Sensor 1 Circuit Malfunction X
P0335 Crankshaft Position Sensor Circuit Malfunction O
P0336 CKP Circuit Range/Performance (More Reference Mark) O
P0340 CMP Circuit Malfunction(Bank1) O
P0420 Catalyst System Efficiency Below Threshold (Bank 1) O
P0441 Evap. Emission Ctrl. System Incorrect Purge Flow O
P0442 Evap. Emission System - Leak Detected (small leak) O
P0444 Evap. Emission System - Purge Ctrl. Valve Circuit Open O
P0445 Evap. Emission System - Purge Ctrl. Valve Circuit Shorted O
Page 3 of 353
P0461 Fuel Level Sensor Circuit Range/Performance O
P0462 Fuel Level Sensor Circuit Low Input O
P0463 Fuel Level Sensor Circuit High Input O
P0464 Fuel Level Sensor Circuit Intermittent O
P0501 Vehicle Speed Sensor Range / Performance O
P0502 Vehicle Speed Sensor Circuit Low Input O
P0503 Vehicle Speec Sensor Circuit O
P0506 Idle Control System - RPM lower than expected O
P0507 Idle Control System - RPM higher than expected O
P0562 System Voltage Low O
P0563 System Voltage High O
P0605 Internal Control Module ROM Error O
P0645 Vehicle Speed Sensor Circuit X
P0650 Malfunction Indicator Lamp(MIL) Control Circuit Malfunction X
P1307 Acceleration Sensor Range/Performance O
P1308 Acceleration Sensor Circuit Low Input O
P1309 Acceleration Sensor Circuit High Input O
P1404 DMTL Heater Malfunction O
P1505 Idle Charge Actuator Signal Low of Coil #1 O
P1506 Idle Charge Actuator Signal High of Coil #1 O
P1507 Idle Charge Actuator Signal Low of Coil #2 O
P1508 Idle Charge Actuator Signal High of Coil #2 O
P1624 Cooling Fan Relay Circuit Low Input X
P1625 Cooling Fan Relay Circuit High Input X
P1765 Torque Reduction Abnormal X
P2096 Post Catalyst Fuel Trim System Too Lean (Bank 1) O
P2097 Post Catalyst Fuel Trim System Too Righ (Bank 1) O
P2187 Fuel Trim Malfunction - System Too Lean at ldle (Additive) O
P2188 Fuel Trim Malfunction - System Too Rich at ldle O
P2191 Fuel Trim Malfunction - System Too Lean at Higher Load (Multiple) O
P2192 Fuel Trim Malfunction - System Too Rich at Higher Load O
P2400 Power Stage (DMTL Motor) - Disconnected O
P2401 Power Stage (DMTL Motor) - Short to ground O
P2402 Power Stage (DMTL Motor) - Short to battery voltage O
P2404 DMTL Malfunction - Pump Motor Current (Current at valve check) O
P2405 DMTL Malfunction - Pump Motor Current (Less than 12mA) O
Page 4 of 353
P2406 DMTL Malfunction - Pump Motor Current (Less than 40mA) O
DMTL Malfunction - Number of unfinished leak detection due to current
P2407 O
change
P2418 Power Stage (DMTL VALVE) - Disconnected O
P2419 Power Stage (DMTL VALVE) - Short to ground O
P2420 Power Stage (DMTL VALVE) - Short to battery voltage O
O : MIL ON & FAULT CODE MEMORY

X : MIL OFF & FAULT CODE MEMORY
Fuel System > General Information > Troubleshooting

BASIC TROUBLESHOOTING
1. Power supply
A. Battery
B. Fusible link
C. Fuse
2. Body ground
3. Fuel supply
A. Fuel line
B. Fuel filter
C. Fuel pump
4. Ignition system
A. Spark plug
B. High-tension cable
C. Ignition coil
5. Emission control system
A. PCV system
B. Vacuum leak
6. Others
A. Ignition timing
B. Idle speed
TROUBLESHOOTING GUIDE CHART
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The number herein means the check order.
Fuel System > General Information > Repair procedures

REPLACEMENT
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FUEL FILTER AND PUMP REPLACEMENT
1. Reduce the internal pressure of the fuel lines and hoses by completing the following operations.
A. After removing the rear seat cushion, disconnect the fuel pump harness.
B. Start the engine. Allow it to stop by itself, then turn the ignition switch OFF.
C. Disconnect the battery negative (-) terminal.
D. Connect the fuel pump harness connector.
2. Remove the eye bolts while holding the fuel filter nuts securely.
Cover the fuel filter with a shop towel to avoid residual gasoline from
splashing.
3. Remove the fuel filter mounting bolts, then remove the fuel filter from the fuel filter clamp.
4. After replacing the fuel filter, check for fuel leaks.
FUEL SENDER REPLACEMENT

1. Remove the fuel tank cap to lower the fuel tank's internal pressure.
2. Remove the fuel sender mounting screws, then remove the fuel sender from the fuel tank.
INSPECTION
SERVICE ADJUSTMENT PROCEDURES
Before adjusting, check that the spark plugs, injectors, idle speed control actuator (ISC actuator), compression
etc. are normal.
CHECK CONDITIONS
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• Engine coolant temperature is 80 to 95°C (176 to 205°F).
• Lights, electric cooling fan and all accessories are off.
• Transaxle is in neutral ("P" or "N" range for A/T vehicles).
• Steering wheel is in a straight forward position (Vehicles with power steering).
1. Install a tachometer to the primary coil side or connect the scan tool to the data link connector.
2. Start and run the engine at curb idle speed.
3. Run the engine for more than 5 seconds at an engine speed of 2,000 to 3,000 rpm. Then, run the engine at idle
for 2 minutes.
4. Read the idling rpm.
Idle speed
SOHC : 800 ± 100 rpm
DOHC : 800 ± 100 rpm
FUEL PUMP OPERATING CHECK

1. Turn the ignition switch OFF.
2. Apply battery voltage to the fuel pump drive connector to check that the pump operates.
The fuel pump is an in-tank type and its operation is hard to hear without removing the fuel tank
cap.
3. Pinch the hose to check that fuel pressure is felt.
FUEL PRESSURE TEST

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1. Press the two taps under the rear seat and raise the seat, then detach the inspection panel of the fuel pump.
2. To reduce the internal pressure of the fuel lines and hoses, first start the engine with the fuel pump disconnected
and wait until it stops by itself.
Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose, otherwise fuel will
spill out.
3. Disconnect the battery negative (-) terminal and then connect the fuel pump harness connector.
4. Using the fuel pressure gauge adapter (09353-24000, 09353-24100, 09353-38000), install the fuel-pressure
gauge to the fuel rail. Tighten the bolt to the specified torque.
Tightening Torque
Fuel pressure gauge to fuel filter :
25 ~ 35 Nm (250 ~ 350 kg·cm, 18 ~ 26 lb·ft)
5. Connect the battery's negative (-) terminal.

6. Apply battery voltage to the terminal for the pump drive and activate the fuel pump. Then, with fuel pressure
applied, check that there is no fuel leak from the pressure gauge or connections.
7. Start the engine and let it idle.
8. Measure the fuel pressure.
350 kPa (3.5 kg/cm², 49.8 psi)

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9. If the result of the measurements made in steps (7) and (8) are not within the standard value, use the table below
to determine the probable cause, and make the necessary repairs.
Condition Probable cause Remedy
Fuel pressure too low 1) Clogged fuel filter. 1) Replace fuel filter.
2) Fuel leak on the return side, caused by 2) Replace fuel pump.
poor seating of the fuel-pressure
regulator.
Fuel pressure too high 1) Sticking fuel-pressure regulator. 1) Replace fuel pump.
2) Clogged or bent fuel return hose or pipe. 2) Repair or replace hose or
pipe.
10. Stop the engine and check for a change in the fuel pressure gauge reading, which should hold for approximately
5 minutes. If the gauge indication drops, observe the rate of drop. Determine and remove the causes according
to the following table.
Condition Probable cause Remedy
Fuel pressure drops slowly after 1) Injector leak. 1) Replace injector.
engine is stopped
Fuel pressure drops immediately 1) The check valve within the fuel pump is 1) Replace fuel pump.
after engine is stopped open.
11. Reduce the pressure in the fuel line.

12. Disconnect the hose and the gauge.
Cover the hose connection with a shop towel to prevent splashing of fuel caused by residual fuel pressure
in the fuel line.
13. Replace the O-ring at the end of the hose.
14. Connect the fuel hose to the delivery pipe and tighten with the specified torque.
15. Check for fuel leaks.
MFI SYSTEM INSPECTION
1. Engine is hard to start or does not start at all.
2. Unstable idle.
3. Poor driveability.
• Before removing or installing any part, read the diagnostic trouble codes and then disconnect the battery
negative (-) terminal.
• Before disconnecting the cable from battery terminal, turn the ignition switch to OFF. Removal or connection of
the battery cable during engine operation or while the ignition switch is ON could cause damage to the ECM.
• The control harnesses between the ECM and heated oxygen sensor are shielded with the shielded ground wires
to the body in order to prevent the influence of ignition noises and radio interference. When the shielded wire is
faulty, the control harness must be replaced.
• When checking the generator for the charging state, do not disconnect the battery '+' terminal to prevent the
ECM from damage due to the voltage
• When charging the battery with the external charger, disconnect the vehicle side battery terminals to prevent
damage to the ECM
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MALFUNCTION INDICATOR LAMP (MIL)
• Catalyst
• Fuel system
• Manifold Absolute Pressure (MAP) Sensor
• Intake Air Temperature Sensor
• Engine Coolant Temperature Sensor
• Throttle Position Sensor
• Upstream Oxygen Sensor
• Downstream Oxygen Sensor Heater
• Downstream Oxygen Sensor
• Upstream Oxygen Sensor Heater
• Injector
• Misfire
• Crankshaft Position Sensor
• Camshaft Position Sensor
• Purge Control Solenoid Valve
• Vehicle Speed Sensor
• Idle Control Valve
• Power Supply
• ECM
• MT/AT Encoding
• Acceleration Sensor
• MIL-on Request Signal
• Power Stage
1. After turning ON the ignition key, ensure that the light illuminatesfor about 5 seconds and then goes out.
2. If the light does not illuminate, check for an open circuit in theharness, a blown fuse or a blown bulb.
SELF-DIAGNOSIS
The ECM monitors the input/output signals (some signals at all timesand the others under specified conditions).
When the ECM detects an irregularity,itrecords the diagnostic trouble code, and outputs the signal to the Data
Linkconnector. The diagnosis results can be read with the MIL or HI-SCAN.Diagnostictrouble codes (DTC) will
remain in the ECM as long as battery power is maintained.The diagnostic trouble codes will, however, be erased
when the battery terminalor the engine control module (ECM) connector is disconnected or by Hi-Scan.
If a sensor connector is disconnected with theignition switch turned on,the diagnostic trouble code (DTC) is
recorded. Inthis case, disconnect the battery negative terminal (-) for 15 seconds ormore, and the diagnosis
memory will be erased.
THE RELATION BETWEEN DTC AND DRIVING PATTERN
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1. When the same malfunction is detected and maintained during twosequential driving cycles, the MIL will
automatically illuminate.
2. The MIL will go off automatically if no fault is detected after3 sequential driving cycles.
3. A Diagnostic Trouble Code(DTC) is recorded in ECM memory whena malfunction is detected after two
sequential driving cycles. The MIL willilluminate when the malfunction is detected on the second driving cycle.
If a misfire is detected, a DTC will be recorded, and the MIL will illuminate,immediately after a fault is first
detected.
4. A diagnostic Trouble Code(DTC) will automatically erase from ECMmemory if the same malfunction is not
detected for 40 driving cycles.
• A "warm-up cycle" means sufficient vehicle operation such thatthe coolant temperature has risen by at
least 40 degrees Fahrenheit from enginestarting and reaches a minimum temperature of 160 degress
Fahrenheit
• A "driving cycle" consists of engine startup, vehicle operationbeyond the beginning of closed loop
operation.
Fuel System > General Information > Specifications

SPECIFICATIONS (1.5 SOHC, 1.6 DOHC)
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Engine displacement 1.5ℓ, 1.6ℓ
Engine Management System (EMS) BOSCH
Fuel tank
- Capacity 45ℓ (11.9 U.S. gal., 9.9 lmp.gal.)
Fuel filter
Fuel pump High pressure type
Electrical, in-tank type
Input sensors
Manifold absolute pressure (MAP)
sensor Piezo-Resistivity type
- Type 0 ~ 5V
- Output voltage
Throttle body Variable resister type
- Throttle position sensor (TP Sensor) 0.3 ~ 0.9V
- Output voltage at idle 4.5 ~ 5.2V
- Output voltage at fully open
Piezoelectric type
Knock sensor
Thermistor type
Intake Air Temperature sensor (IAT
3.3 ~ 3.7V at 20°C (68°F)
Sensor)
- Voltage
Duty type
EVAP Canister Purge solenoid valve 26Ω
- Resistance
Engine coolant temperature sensor (ECT Thermistor type
Sensor) 3.44V ± 0.3 at 20°C (68°F)
- Voltage 1.25V ± 0.3 at 80°C (176°F)
Heated oxygen sensor (HO2S) Zirconia sensor (Heated)
- Output voltage (V) 0 ~ 1V
Vehicle speed sensor
Camshaft position sensor (CMP Sensor) Hall effect sensor
- Output voltage (V) Hall effect sensor
Crankshaft position sensor (CKP Sensor) 0 ~ 5V
- Output frequency (Hz)
Magnetic inductive type
Idle rpm : 600 ~ 900Hz
3000 rpm : 2700 ~ 3300Hz
Output actuators
Injector
- Type Electromagnetic type
- Number 4
- Coil resistance (Ω) 15.9 ± 0.35Ω
Fuel pressure regulator
- Regulator pressure Bulit in Fuel Pump Assembly
350 kPa (3.57 kg/cm², 50.8 psi)
Idle speed control actuator (ISC
Actuator)
- Type
Double coil type
- Control frequency (Hz)
100Hz
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SERVICE STANDARD
Items Engine Specifications Condition
Basic idle RPM A/CON "ON" or "OFF
SOHC 800 ± 100
(N-range)
A/CON "ON" or "OFF
DOHC 800 ± 100
(N-range)
Ignition timing (°) A/CON "OFF" (N-
SOHC 9° ± 5°
(at idle RPM) range)
A/CON "OFF" (N-
DOHC 9° ± 5°
range)
TIGHTENGING TORQUE
Items Nm Kg·cm lb·ft
Delivery pipe installation 10 ~ 15 100 ~ 150 7 ~ 11
Heated oxygen sensor 50 ~ 60 500 ~ 600 37 ~ 44
Crankshaft position sensor installation
9 ~ 11 90 ~ 110 7~8
bolts
Knock sensor installation bolt 16 ~ 25 160 ~ 250 12 ~ 18
Engine coolant temperature sensor
15 ~ 20 150 ~ 200 11 ~ 15
(SOHC)
Engine coolant temperature sensor 25 ~ 30 250 ~ 300 18 ~ 22
(DOHC)
Throttle position sensor installation
1.5 ~ 2.5 15 ~ 25 1.1 ~ 1.8
bolts
Throttle body to surge tank bolts 15 ~ 20 150 ~ 200 11 ~ 15
Accelerator arm bracket 8 ~ 12 80 ~ 120 5.8 ~ 7.2
Fuel pressure gauge to fuel filter 25 ~ 35 250 ~ 350 18 ~ 26
Intake manifold 15 ~ 20 150 ~ 200 11 ~ 15
Accelerator bracket 8 ~ 12 80 ~ 120 5.8 ~ 7.2
MFI control relay 7 ~ 11 70 ~ 110 5.2 ~ 8.1
SEALANT
LOCTITE 962T or equivalent
assembly
Engine coolant temperature sender Three bond No.2310 or equivalent
Fuel System > Engine Control System > Engine Control Module (ECM) > Troubleshooting
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ENGINE CONTROL MODULE (ECM) - POWER GROUND
Check the ground condition of the engine control module.
CIRCUIT DIAGRAM
HARNESS INSPECTION PROCEDURE
MFI CONTROL RELAY

When the ignition switch is on, battery power is supplied to the ECM, the injectors, the MAP sensor, etc. While the
ignition switch is turned on, current flows from the ignition switch through the current relay coil to ground.
CIRCUIT DIAGRAM
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MFI CONTROL RELAY INSPECTION

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1. Check continuity of relay contacts between terminals 5 (+) and 1 (-).
Relay coil (between terminal 2 & 4) Continuity
When de-energized No
When energized Yes
2. If faulty, replace the MFI control relay.
Tightening torque
MFI control relay :
7 ~ 11 Nm (70 ~ 110 kg·cm, 5.2 ~ 8.1 lb·ft)
Fuel System > Engine Control System > Manifold Absolute Pressure Sensor (MAPS) >
Troubleshooting
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP SENSOR)
The manifold absolute pressure (MAP) sensor is a pressure sensitive variable resistor. It measures changes in the
intake manifold pressure which result from engine load and speed changes, and converts this to a voltage output.
The MAP sensor is also used to measure barometric pressure at start up, and under certain conditions, allows the
ECM to automatically adjust for different altitudes. The ECM supplies 5 volts to the MAP sensor and monitors the
voltage on a signal line. The sensor provides a path to ground through its variable resistor. The MAP sensor input
affects fuel delivery and ignition timing controls in the ECM.
CIRCUIT DIAGRAM
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The MIL (Malfunction Indicator Lamp) is ON or the DTC (Diagnostic Trouble Code) is displayed on the HI-
SCAN under the following conditions;
1. When the manifold pressure is 118mb or lower for 0.1 second after turning the ignition key ON.
2. When the manifold pressure is 118mb or lower while the RPM is below 1980rpm.
3. When the manifold pressure is 986mb or higher and the rpm is 2400rpm or more while the accelerator pedal is
released (such as when a vehicle is moving down on a sloping road).
USING HI-SCAN
Check item Data display Check conditions Engine state Test specification
MAP sensor Intake manifold • Engine coolant temperature : IG. KEY "ON" 800 ~ 1080 mb
pressure 80 to 95° (176 to 205°F)
• Lamps, electric cooling fan,
accessory units : ALL OFF
• Transaxle : Neutral (P range Idle 190 ~ 390 mb
for vehicle with A/T)
• Steering wheel : Neutral

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SENSOR INSPECTION
1. Measure the voltage between terminals 1 and 4 of the MAP sensor connectors.
Terminal 4 : MAP sensor ground
Terminal 1 : MAP sensor output
Engine state Test specification
Ignition SW. ON. 4 ~ 5V
At idle 1.14 ± 0.4V
2. If the voltage deviates from the standard value, replace the MAP sensor assembly.
Fuel System > Engine Control System > Intake Air Temperature Sensor (IATS) > Troubleshooting
INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR)
The intake air temperature sensor (IAT Sensor), built-in type in the MAP sensor, is a resistor-based sensor which
detects the intake air temperature. According to the intake air temperature reading, the ECM will control the
necessary amount of fuel injection.
CIRCUIT DIAGRAM
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The MIL is ON or the DTC is displayed on the HI-SCAN under the following condition;
• When the intake air temperature is detected below -40°C or higher than 120°C.
USING HI-SCAN
Intake air Air temperature Ignition switch : ON When 0°C (32°F) 4.0 ~ 4.4V
temperature or engine running
When 20°C (68°F) 3.3 ~ 3.7V
sensor
When 40°C (104°F) 2.5 ~ 2.9V
When 80°C (176°F) 1.0 ~ 1.4V

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SENSOR INSPECTION
1. Using a multimeter, measure the IAT sensor resistance between terminals 3 and 4.
IG. SW. ON Temperature °C (°F) Resistance (kΩ)
0 (32) 4.5 ~ 7.5
20 (68) 2.0 ~ 3.0
40 (104) 0.7 ~ 1.6
80 (176) 0.2 ~ 0.4
2. If the resistance deviates from the standard value, replace the intake air temperature sensor assembly.
Fuel System > Engine Control System > Engine Coolant Temperature Sensor (ECTS) >
Troubleshooting
ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR)
The engine coolant temperature sensor is located in the engine coolant passage of the cylinder head. It detects the
engine coolant temperature and relays signals to the ECM. It employs a thermistor which is sensitive to changes in
temperature. The electric resistance of a thermistor decreases in response to temperature increase. The ECM judges
engine coolant temperature by the sensor output voltage and provides optimum fuel enrichment when the engine is
cold.
CIRCUIT DIAGRAM
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USING HI-SCAN
Engine coolant Sensor temperature Ignition switch : ON When 0°C (32°F) 4.27V ± 0.3
temperature sensor or engine running
When 20°C (68°F) 3.44V ± 0.3
When 40°C (104°F) 2.72V ± 0.3
When 80°C (176°F) 1.25V ± 0.3
SENSOR INSPECTION
1. Remove the engine coolant temperature sensor from the intake manifold.
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2. With the temperature sensing portion of the engine coolant temperature sensor immersed in hot water, check
resistance.
Temperature °C (°F) Resistance (kΩ)
-30 (-22) 22.22 ~ 31.78
-10 (14 8.16 ~ 10.74
0 (32) 5.18 ~ 6.60
20 (68) 2.27 ~ 2.73
40 (104) 1.059 ~ 1.281
60 (140) 0.538 ~ 0.650
80 (176) 0.298 ~ 0.322
90 (194) 0.219 ~ 0.243
3. If the resistance greatly deviates from the standard value, replace the sensor.
INSTALLATION
1. Apply sealant LOCTITE 962T or equivalent to threaded portion.
2. Install engine coolant temperature sensor and tighten it to specified torque.
Tightening torque
SOHC: 15~20 Nm (150~200 kg·cm, 11~15 lb·ft)
DOHC: 25~30 Nm (250~300 kg·cm, 18~22 lb·ft)
3. Connect the harness connector securely.
Fuel System > Engine Control System > Throttle Position Sensor (TPS) > Troubleshooting
THROTTLE POSITION SENSOR (TPS)
The TP Sensor is a rotating type variable resistor that rotates with the throttle body's throttle shaft to sense the
throttle valve angle. As the throttle shaft rotates, the throttle angle of the TP Sensor changes and the ECM detects
the throttle valve opening based on the TPS output voltage.
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CIRCUIT DIAGRAM
1. The TPS signal is important for the control of the automatic transaxle. Shift shock and other trouble may occur if
the sensor is faulty.
2. If the idle condition or acceleration is abnormal, check the TPS connector. (When the TPS connector is not
connected properly, the current data on HI-SCAN can show that the idle state remains off, although the
accelerater pedal is released. This results in the improper idle or acceleration.)
3. Input voltage from throttle position sensor is below 0.1V or above 4.7V when ignition switch is turned on.
USING HI-SCAN
Test
Check item Data display Check condition
specification
Throttle position Throttle angle At idle rpm 5° ~ 16°
sensor
Gradually open Increases
Wide open throttle 80° ~ 98°
USING VOLTMETER
Check item Check condition Test specification
Throttle position sensor output voltage At idle rpm 0.3 ~ 0.9V
(TP Sensor side connector No.1 or ECM harness side
connector No.16) Wide open throttle 4.5 ~ 5.2V

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SENSOR INSPECTION
1. Disconnect the throttle position sensor connector.
2. Measure the resistance between terminals 2 (sensor ground) and terminal 3 (sensor power).
0.7 ~ 3.0 kΩ
3. Connect an analog ohmmeter between terminals 2 (sensor ground) and terminal 1 (sensor output).
4. Operate the throttle valve slowly from the idle position to the full open position, and check that the resistance
changes smoothly in proportion with the throttle valve opening angle.
5. If the resistance is out of specification, or fails to change smoothly, replace the throttle position sensor.
Tightening torque
Throttle position sensor :
1.5 ~ 2.5 Nm (15 ~ 25 kg·cm, 1.1 ~ 1.8 lb·ft)
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Fuel System > Engine Control System > Heated Oxygen Sensor (HO2S) > Troubleshooting
HEATED OXYGEN SENSOR (HO2S)
The heated oxygen sensor senses the oxygen concentration in the exhaust gas, then converts it into a voltage and
then sends this to the ECM. The heated oxygen sensor gives an output of about 800mV when the air fuel ratio is
richer than the theoretical ratio and output of about 100mV when the ratio is leaner (higher oxygen concentration in
exhaust gas.) The ECM controls fuel injection based on this signal so that the air fuel ratio is maintained at the
theoretical ratio.
CIRCUIT DIAGRAM
1. If the heated oxygen sensor is defective, abnormally high emissions may occur.
2. If the heated oxygen sensor check is normal but the sensor output voltage is out of specification, check for the
following items related to the air fuel ratio control system :
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• Faulty injector.
• Air leaks in the intake manifold.
• Faulty mass air flow sensor, purge valve and engine coolant temperature sensor.
• Wiring connection problem.
USING VOLTMETER/HI-SCAN
Check item Check condition Engine condition Test specification
Heated oxygen sensor output Warm-up When decelerating A. 200mV or lower
voltage suddenly from 4000 rpm
When engine is suddenly B. 600 ~ 1000mV
raced
If you release the accelerator pedal suddenly after engine running about 4000 rpm, fuel supply will stop for short
period and the O sensor service data in the HI-SCAN will display values in the A range.
When you suddenly press on the acclerator pedal down, the voltage will reach B range.
When you let the engine idle again, the voltage will fluctuate between ranges A and B. In this case, the O sensor
can be determined as good.
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SENSOR INSPECTION
1. Before checking, warm up the engine until the engine coolant temperature reaches 80 to 95°C (176 to 205°F).
2. Use an accurate digital voltmeter.
Replace the oxygen sensor if there is a malfunction
Tightening torque
Heated oxygen sensor :
50 ~ 60 Nm (500 ~ 600 kg·cm, 37 ~ 44 lb·ft)
Fuel System > Engine Control System > Knock Sensor (KS) > Troubleshooting
KNOCK SENSOR
The knock sensor is attached to the side of the cylinder block to sense engine knocking. A knocking vibration from
the cylinder block is applied as pressure to the piezoelectric element. This vibrational pressure is then converted into
a voltage signal which is relayed to the ECM. If engine knocking occurs, ignition timing is retarded to suppress it.
CIRCUIT DIAGRAM
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HARNESS INSPECTION PROCEDURE

SENSOR INSPECTION
1. Disconnect the knock sensor connector and measure resistance between terminals 1 and 2.
about 5MΩ [at 20°C (68°F)]
2. If the resistance is continuous, replace the knock sensor.
Tightening torque
Knock sensor :
16 ~ 25 Nm (160 ~ 250 kg·cm, 12 ~ 18 lb·ft)
3. Measure the capacitance between terminals 1 and 2.
800 ~ 1600 pF
Fuel System > Engine Control System > Crankshaft Position Sensor (CKPS) > Troubleshooting
CRANKSHAFT POSITION SENSOR (CKP SENSOR)
The crankshaft position sensor, consisted of a magnet and coil, is located next to flywheel. The voltage signal from
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this crankshaft position sensor is relayed to the ECM to indicate engine RPM and the position of the crankshaft.
CIRCUIT DIAGRAM

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SENSOR INSPECTION
1. Disconnect the crankshaft position sensor connector.
2. Measure the resistance between terminals 1 and 2.
0.486 ~ 0.594kΩ at 20°C (68°F)
3. If the resistance deviates greatly from the standard value, replace the sensor.
• Standard value
Clearance between the crankshaft position sensor and crankshaft position sensor wheel :
0.5 ~ 1.5 mm (0.020 ~ 0.059 in.)
• Tightening torque
Crankshaft position sensor :
9 ~ 11 Nm (90 ~ 110 kg·cm, 7 ~ 8 lb·ft)
Fuel System > Engine Control System > Camshaft Position Sensor (CMPS) > Troubleshooting
CAMSHAFT POSITION SENSOR (CMP SENSOR)
The camshaft position sensor (CMP Sensor) senses the TDC point of No.1 cylinder on its compression stroke. Its
signal is fed to the ECM to be used to determine the sequence of fuel injection.
CIRCUIT DIAGRAM
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USING VOLTMETER
Camshaft position sensor output At idle rpm 0 ~ 5V (5 ~ 8 Hz)
voltage
3000 rpm 0 ~ 5V (24 ~ 26 Hz)

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Fuel System > Engine Control System > Vehicle Speed Sensor (VSS) > Troubleshooting
VEHICLE SPEED SENSOR
The vehicle speed sensor is a hall effect sensor that is attached on the output shaft of transaxle. The sensor converts
the transaxle gear revolutions into a pulse signal which is sent to the ECM.
CIRCUIT DIAGRAM
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If there is an open or short circuit in the vehicle speed sensor signal circuit,the engine may stall when the vehicle
decelerates to a stop.
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Fuel System > Engine Control System > Acceleration Sensor > Troubleshooting
ACCELERATION SENSOR
The acceleration sensor is used to sense rough road conditions. The sensor's signal is used by the Engine Control
Module (ECM) to prevent wrongful misfire detection.
CIRCUIT DIAGRAM
USING VOLTMETER
Acceleration sensor output While idling 2.3 ~ 2.7V
voltage
IG. OFF 0V
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Fuel System > Engine Control System > Idle Speed Control Actuator (InodeA) > Troubleshooting
IDLE SPEED CONTROL ACTUATOR (ISC ACTUATOR)
The idle speed actuator is a double coil type driven by separate driver stages in the ECM. Depending on the pulse
duty factor, the equilibrium of the magnetic forces of the two coils will result in different angles of the motor. A
bypass hose line is positioned, in parallel to the throttle valve where the idle speed actuator is inserted.
CIRCUIT DIAGRAM
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Open or short circuit is observed in idle air control system when ignition switch is turned on.
USING HI-SCAN
Check Engine Test
Check item
condition condition specification
Idle speed control actuator Start the engine ISCV Activate
• Actuator test
ACTUATOR INSPECTION
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RESISTANCE MEASUREMENT BETWEEN TERMINALS
1. Disconnect the connector at the idle speed control actuator.
2. Measure the resistance between terminals.
Standard value
Terminal 1 and 2 : 16.6 ~ 18.6Ω
Terminal 2 and 3 : 14.5 ~ 16.5Ω [at 20°C (68°F)]
3. Connect the connector to the idle speed control actuator.
Fuel System > Engine Control System > Throttle Body > Components and Components Location
COMPONENTS
Fuel System > Engine Control System > Throttle Body > Repair procedures
REMOVAL
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The throttle valve must not be removed.

Remove the throttle position sensor.
Except when necessary for replacement, the throttle position sensor must not be removed.
INSPECTION
1. Check the throttle body for cracks.
2. Check for restriction in the vacuum port or passage.
3. Check for interference when moving the accelerator cable.
• Throttle valve set screw was adjusted in the production line with the air volume (0.516 ± 5% g/sec)
during idling. So please DO NOT ADJUST IT voluntarily.
• When the idle rpm is out of specification, check the relevant sensors and their input or output value first.
• The throttle body does not need to be cleaned because carbon in throttle body does not aftect the
system's operation at all.
Fuel System > Engine Control System > Components and Components Location
COMPONENTS
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Page 41 of 353
[1], [2], [4], [9] [3]

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[5], [17] [6]
[7] [11]
[13] [14], [16]
[18] [15]
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[8] [19]
[10]
Fuel System > Fuel Delivery System > Fuel Tank > Components and Components Location
COMPONENTS
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Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures
REMOVAL
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1. Press the two taps under the rear seat and raise the seat, then detach the inspection panel of the fuel pump.
2. To reduce the internal pressure of the fuel lines and hoses, first start the engine with the fuel pump disconnected
and wait until it stops by itself.
Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose, otherwise fuel will
spill out.
3. Disconnect the battery cable from the negative terminal of the battery.
4. Disconnect the high pressure hose from the fuel filter output side, and disconnect the tap for static electricity.
Cover the hose connection with a shop tower to prevent splashing of fuel that could be caused by residual
pressure in the fuel line.
5. Lift up the vehicle.
6. Detach the fuel filler hose and leveling hose.
7. Support the fuel tank with a jack.
8. Remove the fuel tank bands.
9. Remove the fuel tank.
INSTALLATION
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1. Confirm that the pad is fully bonded to the fuel tank, and install the fuel tank by tightening the self-locking nuts.
2. Connect the leveling hose to the tank and at the filler neck by approximately 40mm (1.6 in.).
3. When connecting the filler hose, the end with the shorter straight pipe should be connected to the tank side.
4. Connect the vapor hose. When attaching the vapor hose to the line, be sure that the hose is attached as shown in
the illustration.
5. Connect the high pressure hose to the fuel pump. Be careful that the fuel hose does not twist.
6. Connect the electrical fuel pump connector.
INSPECTION
1. Check the hoses and the pipes for cracks or damage.
2. Check the fuel tank cap for proper operation.
3. Check the fuel tank for deformation, corrosion or cracking.
4. Check the inside of the fuel tank for dirt or foreign material.
5. Check the in-tank fuel filter for damage or restriction.
6. Test the two-way valve for proper operation
7. To check the two-way valve, lightly blow into the inlet and outlet. If air passes through after slight resistance, then
the valve is good.
Page 47 of 353
Fuel System > Fuel Delivery System > Fuel Pump > Troubleshooting
FUEL PUMP
CIRCUIT DIAGRAM

Page 48 of 353
Fuel System > Fuel Delivery System > Injector > Components and Components Location
COMPONENTS
Page 49 of 353
Fuel System > Fuel Delivery System > Injector > Troubleshooting
INJECTORS
The injectors inject fuel according to a signals from the ECM. The volumeof fuel injected by the injector is
determined by the time during which thesolenoid valve is energized.
Page 50 of 353
CIRCUIT DIAGRAM
1. If the engine is difficult to start when it is hot, check low for fuel pressure and injector leaks.
2. If the injector does not operate when the engine is cranked, then check the following :
• Faulty power supply circuit to the ECM or faulty ground circuit.
• Faulty MFI control relay.
• Faulty crankshaft position sensor or camshaft position sensor.
3. If engine idle remains unchanged when fuel injection to the cylinders is cut one after another, check for the
following items about such cylinder :
• Injector and harness.
• Spark plug and high tension cable.
• Compression pressure.
4. If the injection system is OK but the injector drive time is out of specification, check for the following items :
• Poor combustion in the cylinder (faulty spark plug, ignition coil, compression pressure, etc.)
5. The MIL is on or the DTC is displayed on the HI-SCAN under the following condition.
• When the injector itself is faulty.
USING HI-SCAN
Page 51 of 353
Test
Check item Data display Check conditions Engine state
specification
Injectors Injector • Engine coolant temperature : 80 to 95°C Idle rpm 1.5 ~ 4.5 ms
duration (176 to 205°F)
• Lamps, electric cooling fan, accessory 2000 rpm
units : ALL OFF
• Transaxle : Neutral (P range for vehicle 3000 rpm
with A/T)
• Steering wheel : Neutral Racing Increasing
Check HI-SCAN
Check item Type
condition display
Injector Start the engine 01. No.1 Injector Activate
• Actuator 02. No.2 Injector Activate
test
03. No.3 Injector Activate
04. No.4 Injector Activate
INJECTOR INSPECTION
OPERATION CHECK
Using a HI-SCAN :
• Activate the fuel injectors in sequence.
Page 52 of 353
• Check the operating time of the injectors.
1. Using a stethoscope, check the injectors for a clicking sound at idle. Check that the sound is produced at shorter
intervals as the engine speed increases.
Ensure that the sound from an adjacent injector is not being transmitted along the delivery pipe to an
inoperative injector.
2. If a stethoscope is not available, check the injector operation with your finger.
If no vibrations are felt, check the wiring connector, injector, or injection signal from ECM.
RESISTANCE MEASUREMENT BETWEEN TERMINALS

1. Disconnect the connector of the injector and measure the resistance betweenthe two terminals.
15.9 ± 0.35Ω [at 20°C (68°F)]
2. Re-connect the connector to the injector.
Fuel System > Fuel Delivery System > Injector > Repair procedures
REMOVAL
Page 53 of 353
1. Release residual pressure from the fuel line to prevent fuel from spilling.
Cover the hose connection with rags to prevent splashing of fuel that could be caused by residual pressure
in the fuel line.
2. Remove the delivery pipe with the fuel injectors.
• Be careful not to drop any injectors when removing the delivery

pipe.
• Be aware that fuel may flow out when removing the injector.
INSTALLATION
1. Install a new grommet and O-ring to the injector.
2. Apply a coating of solvent, spindle oil or gasoline to the O-ring of the injector.
3. While turning the injector to the left and right, fit it on to the delivery pipe.
4. Be sure the injector turns smoothly.
If it does turn smoothly, the O-ring may be jammed: Remove the injector and re-insert it into the delivery
pipe and recheck.
INSPECTION
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1. Measure the resistance of the injectors between the terminals using an ohmmeter.
Resistance : 15.9 ± 0.35Ω [at 20°C (68°F)]
2. If the resistance is not within specifications, replace the injector.
Fuel System > Fuel Delivery System > Accelerator Pedal and Cable > Components and Components
Location
COMPONENTS
Fuel System > Fuel Delivery System > Accelerator Pedal and Cable > Repair procedures
Page 55 of 353
REMOVAL
1. Remove the bushing and inner cable of the accelerator arm side.
2. After disconnecting the accelerator switch connector, loosen the bolts of the accelerator arm bracket and
remove.
INSTALLATION
1. When installing the return spring and accelerator arm, apply multi-purpose grease around each moving point of
the accelerator arm.
2. Apply sealant to the bolt mounting hole, and tighten the accelerator arm bracket.
Tightening torque
Accelerator arm bracket bolts :
8 ~ 12 Nm (80 ~ 120 kg·cm, 5.8 ~ 7.2 lb·ft)
3. Securely install the resin bushing of the accelerator cable on the end of the accelerator arm.
Page 56 of 353
4. Apply multipurpose grease around the cable end.
INSPECTION
1. Check the inner and outer cable for damage.
2. Check the cable for smooth movement.
3. Check the accelerator arm for deformation.
4. Check the return spring for deterioration.
5. Check the connection of the bushing to end metal fitting.
6. Check that the accelerator switch operates properly.
Fuel System > Troubleshooting > P0030

COMPONENT LOCATION
GENERAL DESCRIPTION
In order to control the emission of the CO, HC and NOx components of the exhaust gas, a heated oxygen sensor
(HO2S), mounted on the front side and rear side of the catalytic converter, detects the oxygen content in the exhaust
gas. The front HO2S signal is used to control air/fuel ratio (closed loop fuel control) and the rear HO2S signal is
used to monitor front HO2S and catalyst for proper operation. The HO2S requires a minimum temperature to
operate properly and provide a closed loop fuel control system. So the HO2S contains a heater element to reduce
warm-up time and ensure proper performance during all driving conditions, which allows for closed loop fuel control
or catalyst monitoring immediately upon engine start-up. The ECM controls this heater element by duty cycle. The
main relay supplies voltage to the heater and the PCM provides a ground circuit for activating the heater.
DTC DESCRIPTION
The PCM determines front HO2S heater fault and sets DTC P0030 if the front HO2S heater control driver inside
the PCM fails or HO2S is not operational after an elapse of predetermined time since engine start or front HO2S tip
temperature is out of normal working range.
Page 57 of 353

Monitoring Strategy ● Heater current check
● Internal resistance > threshold ● Contaminated, deteriorated or aged
Threshold value
f(exh. temp.,heater power) HO2S
● Heater resistance out of reasonable
● Exhaust gas temperature (model) 320-800
range
degC (608 °F~ 1472 °F)
Enable Conditions ● Faulty HO2S heater
● Dew point end detected Battery voltage 10.7-
● Faulty PCM
15.6 V
● Misplaced, bent, loose or corroded
Diagnostic Time ● Continuous terminals
Fail Safe ● Heater open loop control
MONITOR DTC STATUS

This is the inspection procedure to determine whether it is present DTC or memoried one by monitoring the current
signal or by using the function of oscilloscope with Hi-scan pro.
3. Monitor the "A/F CLOSE LOOP" parameter on the scantool.
Fault is intermittent caused by poor contact in the sensor's and/or PCM's connector or was repaired and PCM
memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination,deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle
Repair" procedure.
TERMINAL AND CONNECTOR INSPECTION

Page 58 of 353
damage.
Repair as necessary and go to "Verification of vehicle Repair" procedure

1. Ignition "OFF"
2. Disconnect HO2S sensor connector.
Go to "Control circuit inspection" procedure.
Open or short circuit to chassis ground between HO2S harness connector and control relay.
In case,when checking sensor voltage,the output voltage is 0V.

Possible cause: Blown fuse or open circuit in harness between E/C-J/BOX and terminal 4 of HO2S
heater.

1. Ignition "OFF"
4. Measure voltage between terminal 3 of sensor harness connector.
Page 59 of 353
Check for open or Short to ground in control circuit.

1. Check HO2S heater
Substitute with a known good PCM and check for proper operation. If the problem is corrected, replace
Substitute with a known-good HO2S heater and check for proper operation. If the problem is corrected,
replace HO2S heater and then go to "Verification of Vehicle Repair" procedure.

After a repair, it is essential to verify that the fault has been corrected.
1. Monitor and record the Freeze Frame Data for the Diagnostic Trouble Code (DTC) which has been diagnosed
3. Operate the vehicle within conditions noted in the freeze frame data or enable conditions
SCHEMATIC DIAGRAM
Page 60 of 353

COMPONENT LOCATION
GENERAL DESCRIPTION
In order to control the emission of the CO, HC and NOx components of the exhaust gas, a heated oxygen sensor
(HO2S), mounted on the front side and rear side of the catalytic converter, detects the oxygen content in the exhaust
gas. The front HO2S signal is used to control air/fuel ratio (closed loop fuel control) and the rear HO2S signal is
used to monitor front HO2S and catalyst for proper operation. The HO2S requires a minimum temperature to
operate properly and provide a closed loop fuel control system. So the HO2S contains a heater element to reduce
warm-up time and ensure proper performance during all driving conditions, which allows for closed loop fuel control
or catalyst monitoring immediately upon engine start-up. The PCM controls this heater element by duty cycle. The
main relay supplies voltage to the heater and the PCMprovides a ground circuit for activating the heater.
Page 61 of 353
DTC DESCRIPTION
PCM sets DTC P0031 if the PCM detects that the front HO2S heater control line is short to ground.

Monitoring
● Heater check, low ● Open in battery and control
Strategy
circuit
Threshold value ● Short to ground in control
Enable Conditions ● Open or short circuit circuit (pin 48 to 36)
● Faulty HO2S heater
● Faulty PCM
MONITOR DTC STATUS

This is the inspection procedure to determine whether it is present DTC or memoried one by monitoring the current
signal or by using the function of oscilloscope with Hi-scan pro.
Fault is intermittent caused by poor contact in the sensor's and/or PCM's connector or was repaired and PCM
memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending, corrosion,
Repair" procedure.
TERMINAL AND CONNECTOR INSPECTION

Page 62 of 353
damage.

1. Ignition "OFF"

heater.

1. Ignition "OFF"
Page 63 of 353

Substitute with a known good PCM and check for proper operation. If the problem is corrected, replace

After a repair, it is essential to verify that the fault has been corrected.
SCHEMATIC DIAGRAM
Page 64 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 65 of 353
Monitoring
● Heater check, high
Strategy
Threshold value
Enable circuit
● Short circuit
Conditions ● Faulty HO2S heater
●Faulty PCM
Diagnostic
● Continuous
Time
MONITOR DTC STATUS


damage.
Page 66 of 353

1. Ignition "OFF"

Substitute with a known-good IHO2S heater and check for proper operation. If the problem is corrected,

Page 67 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 68 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring Strategy ● Heater current check
● Internal resistance > threshold ● Contaminated, deteriorated or aged
Threshold value HO2S
f(exh. temp.,heater power)
● Heater resistance out of reasonable
● Catalyst temperature (model) 320-800 degC
range
(608 °F~ 1472 °F)
Enable Conditions ● Faulty HO2S heater
● Dew point end detected Battery voltage 10.7-
● Faulty PCM
15.6 V
● Misplaced, bent, loose or corroded
Diagnostic Time ● Continuous terminals
MONITOR DTC STATUS

3. Monitor the "HO2S(B1/S2) " parameter on the scantool.
Page 69 of 353

damage.

1. Ignition "OFF"

heater.

1. Ignition "OFF"
Page 70 of 353

(1) Measure resistance between terminal 3 and 4 of sensor connector(To sensor side

SCHEMATIC DIAGRAM
Page 71 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 72 of 353
Monitoring
● Heater check, low ● Open in battery and control
Strategy
circuit
Threshold value
Enable Conditions ● Open or short circuit circuit (pin 28 to 35)
Diagnostic Time ● Continuous ● Faulty HO2S heater
● Faulty PCM
MONITOR DTC STATUS

3. Monitor the "HO2S(B1/S2)" parameter on the scantool.

damage.
Page 73 of 353

1. Ignition "OFF"
1. Ignition "OFF"

Page 74 of 353
(1) Measure resistance between terminal 3 and 4 of sensor connector(To sensor side)Specification : 80°C :
8.0~14.0Ω
replace HO2S heater and then go to "Verification of Vehicle Repair" procedure.1. Check HO2S heater

SCHEMATIC DIAGRAM
Page 75 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 76 of 353
Monitoring
● Heater check, high
Strategy
Threshold value
Enable circuit
● Short circuit
Conditions ● Faulty HO2S heater
● Faulty PCM
Diagnostic
● Continuous
Time
MONITOR DTC STATUS

3. Monitor the "HO2S HTR WIRE" parameter on the scantool.

damage.
Page 77 of 353

1. Ignition "OFF"


Page 78 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 79 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Threshold ● Intake manifold pressure : > Max. Threshold or
value < Min. Threshold f(Eng.speed, TPS)
Case1
Enable
● No TPS error detected
Conditions
Threshold
● Intake manifold pressure < 400hPa
value
Case2 ● Poor connection of MAP sensor
Enable ● Faulty MAP sensor
● Engine speed = 0
Conditions ● Faulty TPS
● Dirty air cleaner
Threshold ● |Intake manifold pressure - ambient pressure| <
● Leakage in intake system
value 20hPa
Case3 ● Contact resistance in connections.
Enable ● Faulty PCM
Conditions
● MAP value is substituted by MAP’s model
value.
Fail Safe ● TPS limp home mode.
● Engine speed limitation.
● Minimum operation of EVAP control.
If any codes relating to TPS are present,do all repairs associated with before proceeding this troubleshooting
procedure.
MONITOR DTC STATUS

Page 80 of 353
3. Monitor the "map sensor signal" parameter on the scantool.
It is normal that the output of MAP sensor changes in accordance with TPS angle.

MONITOR SCANTOOL DATA TPS
3. Monitor the "TPS" parameter on the scantool.
4. Is voltege signal increase?
Go to "power Circuit inspection" procedure.
Temporarily install a known good TPS and check for proper operation.
If problem is corrected, replace TPS.
Page 81 of 353
damage.
Go to "Monitor Scantool data TPS" procedure.

1. Ignition "OFF"
2. Disconnect MAP sensor connector.
Open circuit or short circuit to chassis ground between MAP harness connector and reference voltage.
Open circuit or short circuit to chassis ground between MAP harness connector and ECM connector.
In case,when MAP connector is disconnected,the voltage of MAP terminal 2 is 0 V.

Possible cause: Open or short between terminal 33 of PCM and Terminal 2 of MAP

1. Ignition "OFF"
Page 82 of 353
Go to "Component Inspection " procedure.
Open circuit or short circuit to chassis ground between MAP harness connector and signal circuit.
Open circuit between MAP harness connector and ECM harness connector.
In case,when MAP connector is disconnected,the voltage of MAP terminal 1 is 0 V.

GROUND CIRCUIT INSPECTION

1. Ignition "OFF"
4. Measure voltage or resistance between terminal 4 of sensor harness connector and chassis ground.
5. Is measure voltage or resistance within Specification?
In case,when MAP connector is disconnected,the resistance of MAP terminal 4 is

infinite.
Page 83 of 353
1. Air intake system inspection
(1) Check air cleaner for dirt, blockage, or damage.
(2) Check entire air intake system for leaks or blockages such as :
Throttle body
PCV valve
Intake manifold
Gasket beween intake manifold and surge tank
Seals beween intake manifold and fule injectors
Seal beween surge tank and PCV pipe
(3) Is entire air intake system okay?

2. Check PCM
The purpose of checking PCM is to determine whether there is any malfunction of PCM .
(1) Ignition "OFF"
(4) Simulate voltage at terminal 1 of MAP sensor signal connector.
(5) Verify MAP voltage to change while raising or lowering simulation voltage with scan tool within 0.5~3.5 V
(6) Is MAP sensor signal value changed according to simulation voltage ?
Check MAPS for contamination, deterioration, or damage. Clean MAPS with suitable cleaner as necessary and
let air dry before reinstalling. If problem still exists, Substitute with a known-good MAPS and check for proper
operation.
If the problem is corrected, replace MAPS and then go to "Verification of vehicle Repair" procedure

Page 84 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
Page 85 of 353
DTC DESCRIPTION

Monitoring Strategy ● Signal check, low
Threshold value ● Sensor voltage : < 0.25V
Enable Conditions ● Short circuit ● Open in power circuit (pin 33)
● Short to ground in signal circuit (pin
36 to 37)
● MAP value is substituted by MAP’s model ● Faulty MAP sensor
value. ● Faulty PCM
Fail Safe ● TPS limp home mode.
MONITOR DTC STATUS

3. Monitor the "MAP sensor" parameter on the scantool.
Fault is intermittent caused by poor contact in the sensor’s and/or PCM’s connector or was repaired and PCM
memory was not cleared.

Page 86 of 353
damage.
Go to ""Power circuit inspection" procedure.

1. Ignition "OFF"
Open circuit or short circuit to chassis ground between MAP harness connector and reference voltage.
Open circuit or short circuit to chassis ground between MAP harness connector and ECM connector.
1.In case,when MAP connector is disconnected,the voltage of MAP terminal 2 is 0 V.


Page 87 of 353
(1) Ignition "OFF"
(2) Disconnect MAP sensor connector and ECM connector.
(4) Measure resistance between terminal 1 of sensor harness connector and chassis ground.
(5) Measure resistance between terminal 1 and 4 of sensor harness connector
(7) Go to "Component Inspection" procedure.
(8) Short circuit to chassis ground between MAP harness connector and signal circuit.
Short circuit to ground between between MAP harness connector and signal circuit.
1. Check ECM
The purpose of checking PCM is to determine whether there is any malfunction of PCM.
(1) Ignition "OFF"
Page 88 of 353
Check MAPS for contamination, deterioration, or damage. Clean MAPS with suitable cleaner as necessary and let
air dry before reinstalling. If problem still exists, Substitute with a known-good MAPS and check for proper
operation.
If the problem is corrected, replace MAPS and then go to "Verification of vehicle Repair" procedure.

SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 89 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring Strategy ● Signal check, high
Threshold value ● Sensor voltage : > 4.88V ● Open in signal circuit
Enable Conditions ● 1 sec after engine start ● Short to battery in signal circuit (pin
33 to 37)
● Open in ground circuit
● MAP value is substituted by MAP’s model ● Poor connection of MAP sensor
value. ● Faulty MAP sensor
Fail Safe ● TPS limp home mode. ● Faulty PCM
MONITOR DTC STATUS

Page 90 of 353
3. Monitor the "MAP sensor" parameter on the scantool.

damage.
Go to ""Signal circuit inspection" procedure.

Page 91 of 353
(1) Ignition "OFF"
(2) Disconnect MAP sensor connector.
(4) Measure voltage between terminal 1 of sensor harness connector and chassis ground.
Go to "Check for short to power in harness " as below.
Open circuit or short circuit to chassis ground between MAP harness connector and signal circuit.
1.In case,when MAP connector is disconnected,the voltage of MAP terminal 1 is 0 V.


(1) Ignition "OFF"
(2) Disconnect MAP sensor connector and ECM connector.
(4) Measure resistance between terminal 1 and 2 of sensor harness connector.
Page 92 of 353
Go to "Ground Circuit Inspection" procedure.
Short circuit between reference voltage(5V) circuit and signal circuit.

When the terminal 1and 2 of MAP is shorted, the resistence is below 1

ohm.
GROUND CIRUCUIT INSPECTION

1. Ignition "OFF"
1.In case,when MAP connector is disconnected,the resistance of MAP terminal 4 is

infinite.
Page 93 of 353
1. Check ECM
(1) Ignition "OFF"
Check MAPS for contamination, deterioration, or damage. Clean MAPS with suitable cleaner as necessary and
let air dry before reinstalling. If problem still exists, Substitute with a known-good MAPS and check for proper
operation.
If the problem is corrected, replace MAPS and then go to "Verification of vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 94 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 95 of 353
Item Detecting Condition Possible Cause
DTC Strategy ● Rationality check
● Engine start temperature < 30°C(86°F)
Enable ● Idle condition Enable
Conditions ● Vehicle speed < 10km/h(6.2137mph)
case1 ● Coolant temperature > 75°C(167°F)

Threshold ● Max. temp - min. temp(A stuck sensor signal)<
Value =2.25°C(36.05°F)
Diagnostic
● 1 times 45 sec continuous
Time
● No idle and no fuel cut-off
Enable
● Vehicle speed > 50 kph( 31.06856 mile)
Conditions
● Air mass > 40kg/h
case2 Threshold ● Max. temp - min. temp(A stuck sensor signal)< ● Open in signal circuit
Value =2.25°C(36.05°F) ● Short to battery in signal circuit
(Supply 4.8V to pin 42 )
Diagnostic
● 1 times 60 sec continuous ● Open in ground circuit
Time
● Short to ground in signal circuit
Enable (Supply 1V to pin 42 )
Conditions ● Faulty IATS
Threshold ● Faulty PCM
case3 ● Intake air temperature < -30 degC( -22 °F) ● Poor connections between IATS
Value
and ECM
Diagnostic ● Misplaced,bent,loose or corroded
● 15 sec
Time terminals.
Enable
● Idle and no fuel cut-off
Conditions
Threshold
case4 ● Engine coolant temperature > 75°C(167°F)
Value
Diagnostic
● 15 sec
Time
● Last soak time > 5hrs
Enable
● Engine on-time < 40sec
Conditions
● Vehicle speed > 10 kph(6.213712 mile)
case5 Threshold ● Intake temp. - Coolant temp > 10 degC( 50
Value °F)
Diagnostic
● 2 sec
Time
MONITOR DTC STATUS

Page 96 of 353
3. Monitor the "IATS signal" parameter on the scantool.
If the output voltage moves in reverse direction while air temperature changes,the IAT sensor is normal.
When IAT sensor is in malfunction, the default value for IAT is 20.3°C.
Service standard
0°C (32°F) : 4.0~4.4 V
20°C(68°F) : 3.3~3.7 V
40°C(104°F) : 2.5~2.9 V
80°C(176°F) : 1.0~1.4 V

damage.

Page 97 of 353
(1) Ignition "OFF"
(2) Disconnect IAT sensor connector.
In case over 5V : Short circuit to battery between IATS harness connector and PCM harness connector.
In case 0V : Open or short circuit between IATS harness connector and PCM harness connector.
1.In case,when IATS connector is disconnected,the voltage of IATS terminal 3 is 0 V.

Possible cause: Open or short between terminal 42 of PCM and Terminal 3 of IATS

(1) Ignition "OFF"
(2) Disconnect IAT sensor connector and ECM connector.
Go to "Check for short to ground in harness" as below.
Short circuit between MAP sensor power circuit and IATS signal circuit.
Page 98 of 353
(1) Ignition "OFF"
Short circuit between IATS signal circuit and ground circuit.

Short chassis ground between IATS harness connector and PCM harness connector.
1. Ignition "OFF"
2. Disconnect IAT sensor connector.
Open circuit between IATS harness connector and PCM harness connector.
Open circuit between PCM harness connector and chassis ground.
In case,when checking open ground circuit,the resistence is infinite.

Possible cause: Open or short between terminal 36 of PCM and Terminal 4 of
IATS.
Page 99 of 353
1. Check IATS
Measuring the resistence of IAT sensor is to find whether the open circuit exists in the sensor’s inner side.
Open circuit IATS .

The purpose to measure IAT resistence is to decide where open circuit exists and the method is to
check continuity between IAT signal line and ground line.
2. Check PCM
(1) Ignition "OFF"
(4) Simulate voltage at terminal 3 of IAT sensor signal connector.
(5) Verify IATS voltage to change while raising or lowering simulation voltage with scan tool within 0.5~3.5 V
Page 100 of 353
(6) Is IAT sensor signal value changed according to simulation voltage ?

SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 101 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Threshold value ● Measured temperature : < -38.25°C(-36.85°F)
● Idle and no fuel cut-off ● Open in signal circuit
Enable Conditions
● 240 sec after engine start ● Short to battery in signal circuit (pin
Diagnostic Time ● 10.2 sec 42 to 33)
● No failurre detected on ECTS ● Faulty IATS
- The limp home value of IATS depends on ● Faulty PCM
Fail Safe ECTS.
● Failure detected on ECTS
- PCM controls with mapping data.
MONITOR DTC STATUS

Page 102 of 353
Service standard
0°C (32°F) : 4.0~4.4 V
20°C(68°F) : 3.3~3.7 V
40°C(104°F) : 2.5~2.9 V
80°C(176°F) : 1.0~1.4 V

damage.

Page 103 of 353
(1) Ignition "OFF"
(2) Disconnect IAT sensor connector.
In case over 5V : Short circuit to battery between IATS harness connector and PCM harness connector.
In case 0V : Open or short circuit between IATS harness connector and PCM harness connector.
1.In case,when IATS connector is disconnected,the voltage of IATS terminal 3 is 0 V.

Possible cause: Open or short between terminal 42 of PCM and Terminal 3 of IATS

(1) Ignition "OFF"
Short circuit between MAP sensor power circuit and IATS signal circuit.
Page 104 of 353
1. Ignition "OFF"
2. Disconnect IAT sensor connector.
Open circuit between IATS harness connector and PCM harness connector.
In case,when checking open ground circuit,the resistence is infinite.

Possible cause: Open or short between terminal 36 of PCM and Terminal 4 of
IATS.
1. Check IATS
Page 105 of 353
Open circuit IATS .

2. Check PCM
(1) Ignition "OFF"

Page 106 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
Page 107 of 353
DTC DESCRIPTION

Monitoring Strategy ● Signal check, high
Threshold value ● Measured temperature : > 128.25°C(262.85°F)
Enable Conditions ● Idle
● Short to ground in signal circuit (pin
Diagnostic Time ● 0.2 sec 36 to 42)
● No failurre detected on ECTS ● Faulty IATS
- The limp home value of IATS depends on ● Faulty PCM
Fail Safe ECTS.
● Failure detected on ECTS
- PCM controls with mapping data.
MONITOR DTC STATUS

Service standard
0°C (32°F) : 4.0~4.4 V
20°C(68°F) : 3.3~3.7 V
40°C(104°F) : 2.5~2.9 V
80°C(176°F) : 1.0~1.4 V

Page 108 of 353

damage.

(1) Ignition "OFF"
Short circuit between IATS signal circuit and ground circuit.

Short chassis ground between IATS harness connector and PCM harness connector.
Page 109 of 353
1. Check IATS
Open circuit IATS .

2. Check PCM
(1) Ignition "OFF"
Page 110 of 353

SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 111 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring Strategy ● Rathionality check
Threshold
● Measured temp.-Model temp. : < -15°C(5 °F)
value
Enable ● No block heater detected
Case1
Conditions ● Model temp. = f(air mass, current model temp.)
● Poor connections
Diagnostic ● Faulty PCM
● 0.5 sec
Time ● Faulty ETCS
Threshold ● Max temp-Min temp : < 1.5-3 degC(34.7 °F- ● Contaminated, deterriorated or
value 37.4 °F) damaged ETCS
● Faulty thermostat
Enable ● Low heat power mode driving counter > 2 ● Foreign materials fouled ETCS
Case2
Conditions ● High heat power mode driving counter> 2
Diagnostic
Time
● The limp home value of ECTS depends on
Fail Safe
intake air temperature.
MONITOR DTC STATUS

Page 112 of 353
If the output data changes as temoerature changes,the sensor is good.

Service standard
When ECT is 0°C (32°F) : 4.27 ± 0.3 V
When ECT is 20°C(68°F) : 3.44 ± 0.3 V
When ECT is 40°C(104°F) : 2.72 ± 0.3 V
When ECT is 80°C(176°F) : 1.25 ± 0.3 V
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination,deterioration, or

damage.

1. Ignition "OFF"
2. Disconnect ECT sensor connector.
Page 113 of 353
Go to "Ground Circuit Inspection " procedure.
In case over 5V : Short circuit to battery between ECTS harness connector and ECM harness connector.
In case 0V: Open circuit between ECTS harness connector and ECM harness connector.
1.In case,when ECTS connector is disconnected,the voltage at terminal 1 is 0V.

Possible cause : Open or short between Terminal 1 of ETCS connector and terminal 39 of ECM.

1. Ignition "OFF"
Open circuit between ECTS harness connector and PCM harness connector.
In case,when measuring resistence of ground circuit,the resistence is over 1ohm.

Possible cause : Short circuit between PCM ground point and PCM terminal
35
Page 114 of 353
1. Check ECTS
Open circuit ECTS .

2. Check PCM
(1) Ignition "OFF"

Page 115 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 116 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring Strategy ● Signal check, Low
Threshold value ● Measured temperature : < -38.25°C(-36.85°F) ● Open in signal circuit
● Short to battery in signal circuit
Enable Conditions ● Open circuit
Diagnostic Time ● 0.5 sec ● Faulty ECTS
● The limp home value of ECTS depends on ● Faulty PCM
Fail Safe
MONITOR DTC STATUS


Service standard
When ECT is 0°C (32°F) : 4.27 ± 0.3 V
When ECT is 20°C(68°F) : 3.44 ± 0.3
When ECT is 40°C(104°F) : 2.72 ± 0.3 V
When ECT is 80°C(176°F) : 1.25 ± 0.3 V
Page 117 of 353

damage.

(1) Ignition "OFF"
(2) Disconnect ETC sensor connector.
In case over 5V : Short circuit to battery between ECTS harness connector and PCM harness connector.
In case 0V: Open circuit between ECTS harness connector and PCM harness connector.
In case,when ECTS connector is disconnected,the voltage at terminal 1 is 0V.

Possible cause : Open or short between Terminal 1 of ETCS connector and terminal 39 of PCM.
Page 118 of 353
(1) Ignition "OFF"
(2) Disconnect ECT sensor connector and PCM connector.
Short circuit between cluster signal circuit and ECTS signal circuit.
1. Ignition "OFF"

Possible cause : Short circuit between PCM ground point and PCM terminal
35
Page 119 of 353
1. Check ECTS
Open circuit ECTS .

2. Check PCM
The purpose of checking ECM is to determine whether there is any malfunction of ECM .
(1) Ignition "OFF"

Page 120 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 121 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring Strategy ● Signal check, High
● Measured temperature : > 138.75°C (281.75
Threshold value ● Short to ground in signal circuit (pin
°F)
39 to 35)
Enable Conditions ● Short circuit
● Faulty ECTS
Diagnostic Time ● 0.5 sec ● Faulty PCM
● The limp home value of ECTS depends on
Fail Safe
MONITOR DTC STATUS


Service standard
When ECT is 0°C (32°F) : 4.27 ± 0.3 V
When ECT is 20°C(68°F) : 3.44 ± 0.3 V
When ECT is 40°C(104°F) : 2.72 ± 0.3 V
When ECT is 80°C(176°F) : 1.25 ± 0.3 V
Page 122 of 353

damage.

(1) Ignition "OFF"
Short circuit between ECTS signal circuit and ground circuit.

Short chassis ground between ECTS harness connector and PCM harness connector.
Page 123 of 353
1. Check ECTS
Open circuit ECTS .

2. Check PCM
(1) Ignition "OFF"
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.

Page 124 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
Page 125 of 353
DTC DESCRIPTION

● Difference between load signal by Map sensor
Threshold and load signal calculated by TPS : <0.75
value ● Difference between load signal by Map sensor
case1 and load signal calculated by TPS : > 1.25
Enable ● Engine speed > target idle speed
Conditions ● 20sec after engine start
● Modeled relative load - relative load >
● Poor connections
Threshold KLDRLTPS
● Faulty TPS
value ● Modeled relative load - relative load >
● Faulty PCM
KLDRLTPSv
● Open or short in battery circuit
● Off idle ● Dirty air cleaner
● Deviation of fast lambda control factor from 1.0 ● Air leak in intake system
case2 < 0.1 ● Contaminated, deterriorated or
● Engine coolant temperature > 85 degC( 185 damaged TPS
Enable
°F)
Conditions
● Gradient of TPS signal < 0.15 %
● Vehicle speed = 0 kph
● Vehicle speed > 0 kph
● Throttle position value is determined by function
Fail Safe
of engine speed, MAP sensor and idle duty.
MONITOR DTC STATUS

Page 126 of 353
3. Monitor the "TPS signal" parameter on the scantool.
It is normal that the output of TPS changes in accordance with that of MAP sensor.
Service standard
Idle : 0%(250~850mV)
Gradually open : Inccreases
Open fully : 75~85%(4000~4800mV)

damage.

1. Ignition "OFF"
2. Disconnect TPS sensor connector.
Page 127 of 353
Open circuit or short circuit to chassis ground between TPS harness connector and reference voltage.
Open circuit or short circuit to chassis ground between TPS harness connector and PCM connector.
In case,when the TPS connector is disconnected,the voltage of TPS terminal 2 is 0 V.

Possible cause: Open or short between terminal 32 of PCM and Terminal 2 of TPS

1. Ignition "OFF"
Open circuit or short circuit to chassis ground between TPS harness connector and signal circuit.
Open circuit between TPS harness connector and PCM harness connector.


1. Ignition "OFF"
Page 128 of 353
In case,when the TPS connector is disconnected,the voltage of TPS terminal 3 is

infinite.
Possible cause: Open circuit between terminal 17 of PCM and Terminal 3 of TPS
1. Check TPS
Open circuit TPS.

Page 129 of 353
2. Check PCM
The purpose of checking ECM is to determine whether there is any malfunction of ECM .
(1) Ignition "OFF"
(4) Simulate voltage at terminal 1 of TPS sensor signal connector.
(5) Verify TPS voltage to change while raising or lowering simulation voltage with scan tool within 0.5~3.5 V
(6) Is TPS signal value changed according to simulation voltage ?

SCHEMATIC DIAGRAM
Page 130 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 131 of 353
DTC Strategy ● Signal check, low
Threshold value ● Calculated signal from sensor : < 3.14% ● Short to ground in signal circuit (pin
16 to 17)
Enable Conditions ● Engine speed > 600rpm
● Open in power circuit (pin 32)
Diagnostic Time ● 0.02 sec ● Faulty TPS
● Throttle position value is determined by function ● Faulty PCM
Fail Safe
MONITOR DTC STATUS

Service standard
Idle : 0%(250~850mV)
Open fully : 75~85%(4000~4800mV)

damage.
Page 132 of 353

1. Ignition "OFF"
Open circuit or short circuit to chassis ground between TPS harness connector and reference voltage.
Open circuit or short circuit to chassis ground between TPS harness connector and PCM connector.


(1) Ignition "OFF"
(2) Disconnect TPS sensor connector and PCM connector.
Page 133 of 353
Short circuit to ground between TPS harness connector and signal circuit.
In case,when the TPS connector is disconnected,the voltage of TPS terminal 1 is 0

V.
Possible cause: Open or short between terminal 16 of PCM and terminal 1 of
TPS.
1. Check TPS
Open circuit TPS.

Page 134 of 353
2. Check PCM
(1) Ignition "OFF"
Check TPS for contamination, deterioration, or damage. Clean TPS with suitable cleaner as necessary and let air
dry before reinstalling. If problem still exists, Substitute with a known-good TPS and check for proper operation.
If the problem is corrected, replace TPS and then go to "Verification of vehicle Repair" procedure

SCHEMATIC DIAGRAM
Page 135 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 136 of 353
DTC Strategy ● Signal check high ● Open in signal circuit
Threshold value ● Calculated signal from sensor : > 95.7% ● Short to battery in signal circuit (pin
16 to 32)
Enable Conditions ● Engine speed > 600rpm
Diagnostic Time ● 0.02 sec ● Poor connection of TPS
● Throttle position value is determined by function ● Faulty TPS
Fail Safe ● Faulty PCM
MONITOR DTC STATUS

Service standard
Idle : 0%(250~850mV)
Open fully : 75~85%(4000~4800mV)

damage.
Page 137 of 353

(1) Ignition "OFF"
(2) Disconnect TPS sensor connector.
Open circuit or short circuit to chassis ground between TPS harness connector and signal circuit.


(1) Ignition "OFF"
(2) Disconnect TPS sensor connector and PCM connector.
Page 138 of 353

When terminal 1 and 2 of TPS is shorted,the resistance goes below 1Ω.

1. Ignition "OFF"
In case,when the TPS connector is disconnected,the voltage of TPS terminal 3 is

infinite.
Possible cause: Open circuit between terminal 17 of PCM and Terminal 3 of TPS
Page 139 of 353
1. Check TPS
Open circuit TPS.

2. Check PCM
(1) Ignition "OFF"
Check TPS for contamination, deterioration, or damage. Clean TPS with suitable cleaner as necessary and let air
dry before reinstalling. If problem still exists, Substitute with a known-good TPS and check for proper operation.
If the problem is corrected, replace TPS and then go to "Verification of vehicle Repair" procedure
Page 140 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 141 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

DTC Strategy ● Signal check
● Temperature is below the certain values after ● Contaminated, deterriorated or
cranking damaged ETCS
Threshold value ● Faulty thermostat
< 15°C(59°F)/5Min -7 ~ -10°C(19.4 ~ 14°F)
< 10°C(50°F)/2Min : > 10°C(50°F) ● Foreign materials fouled ETCS
● Open in signal circuit (Supply 4V to
Enable Conditions ● Forced the closed loop controller activation
pin 39)
Diagnostic Time ● Faulty ECTS
● The limp home value of ECTS depends on ● Faulty PCM
Fail Safe
MONITOR DTC STATUS

Page 142 of 353
If the output data changes as temoerature changes,the sensor is good

Service standard
When ECT is 0°C (32°F) : 4.27 ± 0.3 V
When ECT is 20°C(68°F) : 3.44 ± 0.3 V
When ECT is 40°C(104°F) : 2.72 ± 0.3 V
When ECT is 80°C(176°F) : 1.25 ± 0.3 V

damage.

Page 143 of 353
(1) Ignition "OFF"
(2) Disconnect ETC sensor connector.
In case over 5V : Short circuit to battery between ECTS harness connector and PCM harness connector.
In case 0V: Open circuit between ECTS harness connector and PCM harness connector.
In case,when ECTS connector is disconnected,the voltage at terminal 1 is 0V.

Possible cause : Open or short between Terminal 1 of ETCS connector and terminal 39 of PCM.

(1) Ignition "OFF"
Short circuit between cluster signal circuit and ECTS signal circuit.
Page 144 of 353
1. Ignition "OFF"

Possible cause : Short circuit between ECM ground point and PCM terminal
35
1. Cooling System inspection
(1) Check cooling system coolant level and fill if low.
(2) Check for a proper cooling system operation. Especially check that cooling and condenser fan working
normally.
(3) Remove the thermostat and check the following items:
1) Stuck or damaged Full open lift : 8.5mm(0.33 in) or more
2)Verify the temperature at which the valve begins to open.Initial valve opening temperature : 82°C(179.6°F)
Full valve opening temperature : 95°C(203°F)
(4) Is a problem found?
Repair as necessary and go to "Verification vehicle Repair" procedure
Go to "Check ECTS" as below.

Page 145 of 353
2. Check ECTS
Open circuit ECTS .

3. Check PCM
(1) Ignition "OFF"


Page 146 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 147 of 353
Monitoring Strategy ● Rathionality check
Threshold
● Sensor voltage : 0.06 ~ 0.4V
value
Enable
Case1 ● Downstream O2 sensor voltage > 0.5 V ● Open in signal and ground circuit
Conditions
● Short to battery in control circuit
Diagnostic ● Faulty HO2S
● 8 sec
Time ● Faulty ECM
Threshold ● Poor connections between HO2S
● Sensor voltage : 0.6-1.08 V and PCM
value
● Misplaced,bent,loose or corroded
Enable
Case2 ● Downstream O2 sensor voltage < 0.1 V terminals.
Conditions
Diagnostic
● 10 sec
Time
Fail Safe ● None
MONITOR DTC STATUS

1.
The data shown above is only for reference and there may be a little difference
actually.
Service standard
For front HO2S
For Rear HO2S
Page 148 of 353

damage.

1. Check for open in harness(signal)
(1) Ignition "OFF"
(2) Disconnect HO2S sensor connector.
(4) Measure voltage between terminal 2 of sensor harness connector and and chassis ground.
Go to "Check for open in harness(ground) " as below.
Open circuit between HO2S harness connector and ECM harness connector.
Page 149 of 353
2. Check for open in harness(ground)
(1) Ignition "OFF"
(2) Disconnect HO2S sensor connector and PCM connector.
(4) Measure resistance between terminal 1 of sensor harness connector and ECM harness connector.
Open circuit between HO2S harness connector and PCM harness connector.
(1) Ignition "OFF"
Go to "Check for short to chassis ground in harness " as below.
Short circuit between HO2S signal circuit and ground circuit.

Page 150 of 353
4. Check for short to chassis ground in harness
(1) Ignition "OFF"
Short circuit between HO2S signal circuit and chassis ground.

Short to chassis ground between PCM harness connector and HO2S harness connector.
1. Check HO2S
(1) Thoroughly check HO2S for contamination,deterioration or damage.
(2) Is HO2S contaminated,deteriorated or damaged?
Substitute with a known-good HO2S and check for proper operation. If the problem is corrected, eplace
HO2S and then go to "Verification of Vehicle Repair" procedure.

2. Check ECM
(1) Ignition "OFF"
(5) Simulate voltage at terminal 2 of HO2S sensor signal connector.
Page 151 of 353
(6) Verify HO2S voltage to change while raising or lowering simulation voltage with scan tool within 0.2 ~ 0.8 V
(7) Is HO2S signal value changed according to simulation voltage ?
It is not permitted to check the inetrnal resistance of HO2S with analog multimeter.

SCHEMATIC DIAGRAM
Page 152 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 153 of 353
Threshold value ● Sensor voltage : < 0.04V
● Short to ground in control circuit (pin
● Downstream O2 sensor voltage > 0.5 V
Enable Conditions 18 to 36)
● Sensor in cold condition
● Faulty HO2S
● 8 sec ● Faulty PCM
Diagnostic Time
● 0.1 sec
Fail Safe ● None
MONITOR DTC STATUS

Service standard
For front HO2S
For Rear HO2S

Page 154 of 353
damage.

(1) Ignition "OFF"
(4) Measure resistance between terminal 2 of sensor harness connector.
Go to "Check for short to ground in harness " as below.

(1) Ignition "OFF"
(4) Measure resistance between terminal 1 , 2 of sensor harness connector.
Page 155 of 353

1. Check HO2S

2. Check PCM
(1) Ignition "OFF"
Page 156 of 353

SCHEMATIC DIAGRAM

Page 157 of 353
COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring
● Signal check , High
Strategy
Threshold value ● Sensor voltage : > 1.08V
Enable circuit
● Short circuit
Conditions ● Faulty HO2S
● 5 sec
Time
Fail Safe ● None
MONITOR DTC STATUS

Page 158 of 353
Service standard
For front HO2S
For Rear HO2S

damage.

Page 159 of 353
(1) Ignition "OFF"
(4) Measure voltage between terminal 2 of sensor harness connector.
Short circuit to battery between HO2S harness connector and PCM harness connector.
In case,when HO2S harness connector disconnected,the output voltage at terminal 2 is 12V.

Possible cause: Short circuit to battery in harness between E/R-J/BOX and terminal 2 of HO2S
heater.
1. Check HO2S

Page 160 of 353
2. Check ECM
(1) Ignition "OFF"

SCHEMATIC DIAGRAM
Page 161 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 162 of 353
Monitoring Strategy ● Response rate ● Abnormal combustion
● Improper fuel pressure
Threshold value ● Average period of 9 oscillation signal : >2.8 sec
● Front and rear HO2S connectors
● Engine speed 1800-2800 rpm reversed.
Enable Conditions ● Engine load 35-75 % ● Faulty fuel delivery system.
● Catalyst temperature > 450 degC(842 °F) ● Leak in intake system.
Diagnostic Time ● Leak in exhaust system.
● Faulty HO2S.
Fail Safe ● None ● Faulty PCM
If any misfire,purge solenoid valve,MAP or HO2S heater codes are present,do all repairs associated with those
codes before proceeding this troubleshooting procedure.
MONITOR DTC STATUS

Service standard
For front HO2S
For Rear HO2S
Page 163 of 353

damage.
SYSTEM INSPECTION
1. Check for Exhaust system
(1) Visually check for leak from exhaust system (especially between TWC converter and front exhaust pipe).
(2) Are any leaks present?

2. Check for Intake system
Check intake system for leaks, cracks, loose connection as follwing items :
(1) Throttle body gasket.
(2) Gasket between intake manifold and surge tank.
(3) Seals between intake manifold and fuel injectors.
(4) Seals between surge tank and PCV valves..
(5) Are any vacuum leaks present?
Go to "Check for fuel pressure " as below.

Page 164 of 353

1. Check HO2S

Page 165 of 353
2. Check PCM
(1) Ignition "OFF"

SCHEMATIC DIAGRAM
Page 166 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 167 of 353
Monitoring Strategy ● Signal check, wiring interruption
Threshold
● Sensor voltage : > 0.2V
value
Enable ● During fuel cut-off
Case1
Conditions ● Downstream O2 sensor voltage > 0.2 V ● Open in signal and ground circuit
Time
● Poor connections between HO2S
Threshold and ECM
● Sensor voltage : > 0.4 ~ 0.6V
value ● Misplaced,bent,loose or corroded
Enable terminals.
Case2
Conditions
Diagnostic
● 5 sec
Time
Fail Safe ● None
MONITOR DTC STATUS

Service standard
For front HO2S
For Rear HO2S
Page 168 of 353

damage.

(1) Ignition "OFF"
Page 169 of 353
(1) Ignition "OFF"
(4) Measure resistance between terminal 1 of sensor harness connector and ECM harness connector.
1. Check HO2S

2. Check PCM
The purpose of checking ECM is to determine whether there is any malfunction of ECM.
(1) Ignition "OFF"
Page 170 of 353

SCHEMATIC DIAGRAM
Page 171 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 172 of 353
● Open HO2S
● Counter of ushk > 1.25V during 0.05sec after
● Short HO2S
Threshold value heater on-> off
● Faulty HO2S .
: > 5 times
● Faulty PCM .
● No signal check high error ● Poor connections between HO2S
Enable Conditions
● Heater on->off counter > 10 times and ECM.
Diagnostic Time ● Misplaced,bent,loose or corroded
terminals.
Fail Safe ● None
MONITOR DTC STATUS

Service standard
For front HO2S
For Rear HO2S

Page 173 of 353

damage.

1. Check for short to heater control in harness
(1) Ignition "OFF"
Short circuit between HO2S signal circuit and heater control circuit.
1. Check HO2S

Page 174 of 353
2. Check PCM
(1) Ignition "OFF"

SCHEMATIC DIAGRAM
Page 175 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 176 of 353
Monitoring
● Signal check, low
Strategy
Threshold value ●Sensor voltage : < 0.04V
circuit (pin 55 to 35)
Enable Conditions ● Short circuit ● Faulty HO2S
Diagnostic Time ● 5 sec ● Faulty PCM
Fail Safe ● None
MONITOR DTC STATUS

Service standard
For front HO2S
For Rear HO2S

Page 177 of 353
damage.

(1) Ignition "OFF"

(1) Ignition "OFF"
Page 178 of 353

1. Check HO2S

2. Check PCM
The purpose of checking ECM is to determine whether there is any malfunction of ECM.
(1) Ignition "OFF"
Page 179 of 353

SCHEMATIC DIAGRAM

Page 180 of 353
COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring
● Signal check , High
Strategy
Threshold value ● Sensor voltage : > 1.08V
Enable circuit
● Short circuit
Conditions ● Faulty HO2S
● 5 sec
Time
Fail Safe ● None
MONITOR DTC STATUS

Page 181 of 353
Service standard
For front HO2S
For Rear HO2S

damage.

Page 182 of 353
(1) Ignition "OFF"
(4) Measure voltage between terminal 2 of sensor harness connector.
Short circuit to battery between HO2S harness connector and PCM harness connector.
In case,when HO2S harness connector disconnected,the output voltage at terminal 2 is 12V.

Possible cause: Short circuit to battery in harness between E/R-J/BOX and terminal 2 of HO2S
heater.
1. Check HO2S

Page 183 of 353
2. Check PCM
(1) Ignition "OFF"

SCHEMATIC DIAGRAM
Page 184 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 185 of 353
Monitoring Strategy ● Signal check, wiring interruption
Threshold
● Sensor voltage : 0.4 ~ 0.52V
value
Enable
Case1 ● Supply 0.45V
Conditions ● Open in signal and ground circuit
● 600 sec ● Faulty ECM
Time
● Poor connections between HO2S
Threshold and PCM
● Internal resistance > 40 kΩ
value ● Misplaced,bent,loose or corroded
Enable ● Catalyst temperature (model) > 600 degC(1112 terminals.
Case2
Conditions °F)
Diagnostic
Time
Fail Safe ● None
MONITOR DTC STATUS

Service standard
For front HO2S
For Rear HO2S
Page 186 of 353

damage.

(1) Check for open in harness(signal)
Page 187 of 353
(1) Ignition "OFF"
(4) Measure resistance between terminal 1 of sensor harness connector and PCM harness connector.
1. Check HO2S

2. Check PCM
(1) Ignition "OFF"
Page 188 of 353

SCHEMATIC DIAGRAM
Page 189 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 190 of 353
DTC Strategy ● Circuit continuity check
● Short to ground in control circuit
Threshold value ● Shorted or disconnected
(pin 70 to chassis ground)
Enable Conditions ● Not monitor ● Open in control circuit (pin 70)
Diagnostic Time ● Faulty fuel pump relay
● Faulty PCM
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "Fuel pump relay" parameter on the scantool.
Service standard
Ignition switch ON : ON 1.5 sec →OFF
Engine running : ON

damage.
Page 191 of 353

1. Ignition "OFF"
2. Disconnect connect fuel pump relay.
4. Measure voltage between terminal 1 and 5 of fuel pump relay harness connector and chassis ground.
Open circuit or short circuit to chassis ground between fuel pump relay and control relay.
1. Ignition "OFF"
2. Connect fuel pump relay and PCM connector.
4. Measure voltage between terminal 70 of ECM harness connector and chassis ground.
Short circuit to chassis ground between fuel pump relay signal circuit and PCM harness connector.
Open circuit between fuel pump relay signal circuit and PCM harness connector.
Open circuit pump relay.
Page 192 of 353
1. In case the voltage at terminal 70 of PCM is 0V.

Possible cause: Open circuit between fuel pump relay and ECM, or open coil in fuel pump relay
1. Check fuel pump relay
(1) Ignition "OFF"
(2) Disconnect the fuel pump relay
(3) Apply 12V and a ground to 3 and 5 terminals of the fuel pump relay
(4) Measure resistance between terminal 1 and 2 of fuel pump relay connector(To sensor side)
Substitute with a known-good control relay and check for proper operation. If the problem is corrected,
replace control relay and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 193 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 194 of 353
Threshold
● Shorted or disconnected ● Open in battery circuit
value
Enable ● Short to ground in control
● Open circuit
Conditions circuit
● Faulty injector’s
Diagnostic
● Continuous ● Faulty PCM
Time
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "INJ duration" parameter on the scantool.
The Injector operating time should be checked in P or N range, warmed-up and idling condition.
Service standard
In idling: 2.2 ~ 5.0ms
2500 rpm : 2.0 ~ 5.0ms
Page 195 of 353

damage.

1. Ignition "OFF"
2. Disconnect INJ connector.
Open circuit or short circuit to chassis ground between INJ harness connector and control relay.
1.In case the voltage between terminal 1 of injector and terminal 27,6,7 and 47 of PCM is 1V
respectively.
Suspect area : Open or short circuit of power line from injector to PCM.

Page 196 of 353
(1) Ignition "OFF"
(2) Connect INJ connector and PCM connector.
(4) Measure voltage between terminal 27 of ECM harness connector and chassis ground..
Open or Short circuit to chassis ground between INJ harness connector and PCM harness connector.
(1) Ignition "OFF"
(2) Disconnect INJ connector and PCM connector.
(4) Measure resistance between terminal 2 of sensor harness connector and chassis ground..
Short circuit between injector control circuit and chassis ground.

Page 197 of 353
1. Check INJ
Substitute with a known-good INJ and check for proper operation. If the problem is corrected, replace
INJ and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 198 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 199 of 353
DTC Strategy ● Signal check, High
Threshold
● Shorted or disconnected
value
Enable circuit
● Open circuit
Conditions ● Faulty injector’s
● Continuous
Time
Fail Safe ● None
MONITOR DTC STATUS

Service standard
2500 rpm : 2.0 ~ 5.0ms
Page 200 of 353

damage.

(1) Ignition "OFF"
(2) Disconnect INJ connector.
(4) Measure voltage between terminal 2 of sensor harness connector and chassis ground..
Short circuit to battery power 12V between injector harness connector and control relay.
1.In case the voltage of terminal 2 is measured 12V when the connector is
disconnected.
Suspect area: Short to battery power line after fuse(15A for injector) when IG on.
Page 201 of 353
1. Check INJ

SCHEMATIC DIAGRAM
Page 202 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 203 of 353
Threshold
value
● Open circuit
Conditions circuit
Diagnostic ● Faulty injector’s
Time
Fail Safe ● None
MONITOR DTC STATUS

Service standard
2500 rpm : 2.0 ~ 5.0ms
Page 204 of 353
ault is intermittent caused by poor contact in the sensor’s and/or PCM’s connector or was repaired and PCM
memory was not cleared.

damage.

1. Ignition "OFF"
respectively.

Page 205 of 353
(1) Ignition "OFF"
(1) Ignition "OFF"

Page 206 of 353
1. Check INJ

SCHEMATIC DIAGRAM
Page 207 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 208 of 353
Threshold
value
Enable circuit
● Open circuit
● Continuous
Time
Fail Safe ● None
MONITOR DTC STATUS

Service standard
2500 rpm : 2.0 ~ 5.0ms
Page 209 of 353

damage.

(1) Ignition "OFF"
disconnected.
Page 210 of 353
1. Check INJ

SCHEMATIC DIAGRAM
Page 211 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 212 of 353
Threshold
value
● Open circuit
Conditions circuit
Time
Fail Safe ● None
MONITOR DTC STATUS

Service standard
2500 rpm : 2.0 ~ 5.0ms
Page 213 of 353

damage.

1. Ignition "OFF"
o to "Control circuit insepction" procedure.
respectively.

Page 214 of 353
(1) Ignition "OFF"
(1) Ignition "OFF"

Page 215 of 353
1. Check INJ

SCHEMATIC DIAGRAM
Page 216 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 217 of 353
Threshold
value
Enable circuit
● Open circuit
● Continuous
Time
Fail Safe ● None
MONITOR DTC STATUS

Service standard
2500 rpm : 2.0 ~ 5.0ms
Page 218 of 353

damage.

(1) Ignition "OFF"
In case the voltage of terminal 2 is measured 12V when the connector is

disconnected.
Page 219 of 353
1. Check INJ

SCHEMATIC DIAGRAM
Page 220 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 221 of 353
Threshold
value
● Open circuit
Conditions circuit
Time
Fail Safe ● None
MONITOR DTC STATUS

1.
The Injector operating time should be checked in P or N range, warmed-up and idling
condition.
Service standard
2500 rpm : 2.0 ~ 5.0ms
Page 222 of 353

damage.

1. Ignition "OFF"
respectively.

Page 223 of 353
(1) Ignition "OFF"
(1) Ignition "OFF"

Page 224 of 353
1. Check INJ

SCHEMATIC DIAGRAM
Page 225 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 226 of 353
Threshold
value
Enable circuit
● Open circuit
● Continuous
Time
Fail Safe ● None
MONITOR DTC STATUS

Service standard
2500 rpm : 2.0 ~ 5.0ms
Page 227 of 353

damage.

(1) Ignition "OFF"
disconnected.
Page 228 of 353
1. Check INJ

SCHEMATIC DIAGRAM
Page 229 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 230 of 353
Monitoring
● Signal check
Strategy
● Reference level voltage : < lower
limit,f(rpm)
Threshold value
Case1 ● Reference level voltage : < higher
limit,f(rpm)
Enable
● Knock control enabled
Conditions ● Short to ground in signal circuit
● No dynamic knock control
● Open in signal circuit
Monitoring ● Faulty Knock sensor
● Circuit continuity check, pulse test
Strategy ● Faulty PCM
Case2
● Integrator value difference(End value -
Threshold value
Startvalue) : <3.7V
Monitoring
● Circuit continuity check, zero test
Strategy
Case3
● Integrator offset : > 0.234V
Threshold value
● Intergator grasient : > 40 ~ 60V/sec
Enable Conditions ● Engine speed 1200-5200 rpm
● The ignition angle correction is determined
Fail Safe
by function of engine speed, mass air fiow.
MONITOR DTC STATUS

Page 231 of 353
Specification
3000 rpm : 29 ~ 49° BTDC

damage.

(1) Ignition "OFF"
(2) Disconnect Knock sensor connector.
Page 232 of 353
In case over 5V : Short circuit to battery between Knock sensor harness connector and PCM harness
connector.
In case 0V: Open or Short circuit between Knock sensor harness connector and PCM harness connector.
In case,when knock sensor connector is disconnected,the voltage at terminal 1 is 0V.

Possible cause : Open or short to ground and faulty PCM.

(1) Ignition "OFF"
(2) Disconnect Knock sensor connector and PCM connector.
Short circuit to chassis ground between Knock sensor harness connector and PCM harness connector.
Short circuit between Knock sensor signal line and ground line.
1. Ignition "OFF"
2. Disconnect Knock sensor connector.
Page 233 of 353
4. Measure resistance or voltage between terminal 1 of sensor harness connector and chassis ground.
Open circuit between Knock sensor harness connector and PCM harness connector.
In case,when checking the open ground circuit,the resistance is infinite.

Possible cause : Open circuit in ground line.
1. Check Knock sensor
Substitute with a known-good Knock sensor and check for proper operation. If the problem is corrected,
replace Knock sensor and then go to "Verification of Vehicle Repair" procedure.

Page 234 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 235 of 353
Monitoring
● Signal check
Strategy ● Open in signal circuit
Threshold value ● No signal during cranking : 8 times ● Open in ground circuit (pin 34
to 15)
Enable Conditions ● Phase sensor signal enabled
● Faulty CKPS
Diagnostic Time ● Cranking ● Faulty PCM
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "CKPS signal" parameter on the scantool.
Specification
Engine running : on

damage.
Page 236 of 353

(1) Ignition "OFF"
(2) Disconnect CKP sensor connector.
Open circuit or short circuit to chassis ground between CKPS harness connector and ECM harness
connector.
In case,when CKPS connector is disconnected,the voltage at terminal 1 is 0V.

Possible cause : Open circuit in signal line or faulty PCM

(1) Ignition "OFF"
(2) Disconnect CKP sensor connector and PCM connector.
Page 237 of 353
Short circuit to chassis ground between CKPS harness connector and PCM harness connector.
Short circuit between CKPS signal circuit and ground circuit.
1. Ignition "OFF"
2. Disconnect CKP sensor connector.
Open circuit or short circuit to chassis ground between CKPS harness connector and PCM harness
connector.

Possible cause : Open circuit in ground line or faulty PCM
Page 238 of 353
1. Check PCM
(1) Ignition "OFF"
(4) Simulate frequency at terminal 1 of CKP sensor signal connector.
(5) Verify CKPS frequency to change while raising or lowering simulation frequency with scan tool within 25 Hz
(6) Is injector operating sound heard in propotion to simulation frequency ?
Check CKPS for contamination, deterioration, or damage. Clean CKPS with suitable cleaner as necessary and let
air dry before reinstalling. If problem still exists, Substitute with a known-good CKPS and check for proper
operation.
If the problem is corrected, replace CKPS and then go to "Verification of vehicle Repair" procedure

SCHEMATIC DIAGRAM
Page 239 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 240 of 353
Monitoring Strategy ● Reference mark check
Threshold value ● No reference mark : > 20times
● poor connections
● Vehicle speed < 1 kph( 0.621371 mile) or > 25 ● Faulty target wheel tolerance
Enable Conditions kph(15.53428 mile) ● Out of allowable air gap
● Idle engine speed > Target speed - 100 rpm ● Faulty CKPS
● Faulty PCM
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "CKPS signal" parameter on the scantool.
Specification
Engine running : on

damage.
Page 241 of 353

(1) Ignition "OFF"
(2) Disconnect CKP sensor connector and PCM connector.
Short circuit to chassis ground between CKPS harness connector and PCM harness connector.
Short circuit between CKPS signal circuit and ground circuit.
1. Ignition "OFF"
2. Disconnect CKP sensor connector.
Page 242 of 353
Open circuit or short circuit to chassis ground between CKPS harness connector and PCM harness
connector.

Possible cause : Open circuit in ground line or faulty PCM
1. CKPS air gap Inspection
(1) Remove CKPS and calculate air gap between sensor and tooth wheel.
(2) Measure distance from hosing to tooth on tooth wheel.(Measurement "A")
(3) Measure from mounting surface on sensor to sensor tip.(Measurement "B")
(4) Subtract "B" from "A" = air gap
(5) Are air gap within specification?
Fauity air gap.

Page 243 of 353
2. Check PCM
(1) Ignition "OFF"
(4) Simulate frequency at terminal 1 of CKP sensor signal connector.
(5) Verify CKPS frequency to change while raising or lowering simulation frequency with scan tool within 25 Hz
(6) Is injector operating sound heard in propotion to simulation frequency ?
Check CKPS for contamination, deterioration, or damage. Clean CKPS with suitable cleaner as necessary and let
air dry before reinstalling. If problem still exists, Substitute with a known-good CKPS and check for proper
operation.
If the problem is corrected, replace CKPS and then go to "Verification of vehicle Repair" procedure

SCHEMATIC DIAGRAM
Page 244 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 245 of 353
Monitoring Strategy ● Signal check
● Signal high and no phase edge : 12 times
Threshold value ● Signal low and no phase edge : 12 times ● Open in signal circuit
● Irregular phase edge : 12times ● Open in battery and ground circuit
Enable Conditions ● Sensor signal requested
● Short to battery in signal circuit
Diagnostic Time ● Faulty CMPS
● The normal serial fuel injection starts with ● Faulty PCM
Fail Safe crankshaft sensor signal.
● Ignition timing is retarded.
MONITOR DTC STATUS

1. Engine "ON"
2. Monitor wave form at the terminal 2 of CMPS.

damage.
Go to ""Power circuit inspection" procedure.

1. Ignition "OFF"
Page 246 of 353
2. Disconnect CMP sensor connector.
Open or short circuit to chassis ground between CMPS harness connector and battery power circuit.
In case,when CMPS connector is disconnected,the voltage at terminal 1 is 0V.

Possible cause : Open or short circuit between I/P-J/BOX fuse(15A) and CMPS terminal 1.

(1) Ignition "OFF"
(2) Disconnect CMP sensor connector.
Page 247 of 353
Open or short circuit between CMPS harnece connector and PCM harness connector.
Fault PCM
In case,when CMPS connector is disconnected,the voltage at terminal 2 is 0V.

Possible cause : Open signal line or faulty PCM

(1) Ignition "OFF"
(2) Disconnect CMP sensor connector and PCM connector.
Short circuit to ground between CMPS harness connector and PCM harness connector.
Short circuit between CMPS signal circuit and ground circuit.
Page 248 of 353
(1) Ignition "OFF"
(2) Disconnect CMP sensor connector and PCM connector.
Short circuit between CMPS signal circuit and power circuit.

1. Ignition "OFF"
2. Disconnect CMP sensor connector.
Open circuit between Fuel sender harness connector and chassis ground.

Page 249 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION
Page 250 of 353
● Consumed fuel (model) - consumed fuel (actual)
Threshold value ● Poor connections
> 10 L or < -10 L
● Faulty TPS
● Fuel level signal is valid ● Faulty PCM
● Consumed fuel (model) > 15 L ● Open or short in battery circuit
Enable Conditions
● Fuel level change at instant < 0.4 L ● Dirty air cleaner
● 15 sec after ignition on ● Air leak in intake system
● Contaminated, deterriorated or
damaged TPS
● Throttle position value is determined by function
Fail Safe
MONITOR DTC STATUS

3. Monitor DTC(Diagnostics Trouble Code) on the scantool.
Service standard
FULL : 0.3 ~ 0.9 V
EMPTY : 4.5 ~ 5.2 V
4. Is the same DTC displayed again?
Fault is intermittent caused by poor contact in the sensors and/or PCM’s connector or was repaired and PCM
memory was not cleared.Thoroughly check connectors for looseness, poor connection, bending, corrosion,
Repair" procedure.

damage.
Page 251 of 353

(1) Ignition "OFF"
Open circuit or short circuit to chassis ground between Fuel sender harness connector and PCM
connector.
In case,when the Fuel sender connector is disconnected,the voltage of Fuel sender terminal 3 is 0 V.
Possible cause: Open or short between terminal 21 of PCM and terminal 3 of Fuel sender.

(1) Ignition "OFF"
(2) Disconnect Fuel sender connector and PCM connector.
(4) Measure resistance between terminal 1 and 3 of Fuel sender harness connector.
Page 252 of 353
Short circuit to ground between Fuel sender harness connector and sender signal circuit.
In case,when the Fuel sender connector is disconnected,the voltage of Fuel sender terminal 3 is 0
V.

1. Ignition "OFF"
2. Disconnect Fuel sender connector.
In case,when the Fuel sender connector is disconnected,the voltage of Fuel sender terminal 3 is
infinite.
Possible cause: Open circuit between terminal 3 of Fuel sender and chassis ground.
Page 253 of 353
1. Check Fuel sender
(1) Ignition "OFF"
Substitute with a known-good Fuel sender and check for proper operation. If the problem is corrected,
replace Fuel sender and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 254 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 255 of 353
Threshold value ● Voltage < 0.1V
● Short to ground in signal
Enable circuit (pin 21 to ground)
● Shorted circuit
Conditions ● Faulty Fuel sender
Diagnostic Time ● 5 sec ● Faulty PCM
Fail Safe ● None
MONITOR DTC STATUS

Service standard
FULL : 0.2 ~ 0.7 V
EMPTY : 4.5 ~ 5.2 V
Repair" procedure.

damage.

Page 256 of 353
(1) Ignition "OFF"
(2) Disconnect Fuel sender connector and PCM connector.
(4) Measure resistance between terminal 1 and 3 of Fuel sender harness connector.
(5) Measure resistance between terminal 1 and 3 of Fuel sender harness connector and chassis ground.
Short circuit to ground between Fuel sender harness connector and sender signal circuit.
(1) Ignition "OFF"

Page 257 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
Page 258 of 353
DTC DESCRIPTION

DTC Strategy ● Signal check high
Threshold
● Voltage > 4.9V ● Open in signal circuit
value
● Short to battery in
Enable signal circuit
● Open circuit
Conditions ● Open in ground circuit
● Faulty Fuel sender
Diagnostic
Time
Fail Safe ● None
MONITOR DTC STATUS

Service standard
FULL : 0.2 ~ 0.7 V
EMPTY : 4.5 ~ 5.2 V
Repair" procedure.

damage.
Page 259 of 353

(1) Ignition "OFF"
Go to "Ground Circuit Inspection" procedure
Open circuit or short circuit to chassis ground between Fuel sender harness connector and PCM
connector.
In case,when the Fuel sender connector is disconnected,the voltage of Fuel sender terminal 1 is 0 V.

1. Ignition "OFF"
2. Disconnect Fuel sender connector.
Page 260 of 353
In case,when the Fuel sender connector is disconnected,the voltage of Fuel sender terminal 3 is
infinite.
Possible cause: Open circuit between terminal 3 of Fuel sender and chassis ground.
(1) Ignition "OFF"

SCHEMATIC DIAGRAM
Page 261 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 262 of 353
Threshold ● No vehicle speed signal(during injection) : <
value 3.75kph(2.330142 mile)
case1 ● Engine speed > 3000 rpm
Enable ● Open in signal circuit
● Engine load > 50 % ● Open in battery and ground circuit
Conditions
● Coolant temperature > 65 degC(149 °F)
Threshold ● No vehicle speed signal (during fuel cut-off) < 5 ● Short to battery in signal circuit
value kph(3.106856 mile) ● Faulty VSS
case2 ● Faulty PCM
Enable ● Engine speed 1520-4000 rpm
Conditions ● Coolant temperature > 65 degC(149 °F)
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "VSS signal" parameter on the scantool.
Service standard
Approximately 40 Km/h

Page 263 of 353
damage.

1. Ignition "OFF"
2. Disconnect VSS sensor connector.
Open circuit or short circuit to chassis ground between VSS harness connector and battery power circuit.
In case,when the connector of VSS is disconnected, the voltage of terminal 3 is 1V.

Possible cause:Open circuit or short circuit after I/P-J/BOX fuse(10A)

Page 264 of 353
(1) Ignition "OFF"
(2) Disconnect VSS sensor connector.
Open or short circuit between VSS harnece connector and PCM harness connector.
Faulty PCM
1. In case,when the connector of VSS is disconnected, the voltage of terminal 2 is 0V.

Possible cause: If the terminal 2 voltage of VSS is 0V, the possible cause is likely to be open or
bad PCM.
2. The voltage of terminal 2 is about 6.5~7.5V when the VSS connector is disconnected.

When the voltage of VSS terminal 2 is 0V, the inspection of short circuit is recommended to find open or short
circuit of signal line.
(1) Ignition "OFF"
(2) Disconnect VSS sensor connector and PCM connector.
Page 265 of 353
short circuit to chassis ground between VSS harness connector and PCM harness connector.
short circuit between VSS signal circuit and ground circuit.
1. Ignition "OFF"
Open circuit between VSS harnece connector and Chassis ground.

1. Check PCM
(1) Ignition "OFF"
Page 266 of 353
(4) Is VSS sensor signal value changed according to simulation voltage ?
Check VSS for contamination, deterioration, or damage. Clean VSS with suitable cleaner as necessary
and let air dry before reinstalling. If problem still exists, Substitute with a known-good VSS and check for
proper operation.
If the problem is corrected, replace VSS and then go to "Verification of vehicle Repair" procedure

SCHEMATIC DIAGRAM

Page 267 of 353
COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring ● Open in signal circuit
● Signal check
Strategy ● Open in battery and ground
circuit
Threshold value ● Constant vehicle speed > 20 sec
● Short to ground in signal
Enable circuit
● Vehicle speed > 0 kph(0 mile)
Conditions ● Short to battery in signal
Diagnostic Time ● 20 sec circuit
● Faulty VSS
MONITOR DTC STATUS

Page 268 of 353
Service standard

damage.

1. Ignition "OFF"
Page 269 of 353


(1) Ignition "OFF"
Page 270 of 353
Faulty PCM

bad PCM.

(1) Ignition "OFF"
1. Ignition "OFF"
Page 271 of 353

1. Check PCM
(1) Ignition "OFF"
proper operation.

Page 272 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 273 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring Strategy ● Signal check ● Open in signal circuit
● Open in battery and ground
Threshold value ● Vehicle speed > 275 kph(170.877078 mile)
circuit
Enable Conditions ● Short to ground in signal circuit
Diagnostic Time ● Short to battery in signal circuit
● Faulty VSS
MONITOR DTC STATUS

Service standard

Page 274 of 353
damage.

1. Ignition "OFF"


(1) Ignition "OFF"
Page 275 of 353
Faulty PCM

bad PCM.

(1) Ignition "OFF"
1. Ignition "OFF"
Page 276 of 353

1. Check PCM
(1) Ignition "OFF"
proper operation.

Page 277 of 353
SCHEMATIC DIAGRAM

Page 278 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring Strategy ● Rationality check, low
Threshold value ● Eng speed - desired eng speed : 200rpm
● Intake hose
● Vehicle speed = 0
● Carbon fouied throttle plate -
● Coolant temperature > 75 degC(167 °F)
Accelrator cable adjussted improperly
Enable Conditions ● Intake air temperature > 9.75 degC(49.55 °F)
● faulty ISCA
● Altitude (model) < 2500 m
● faulty TPS
● I-controller < -14.8 %
● Faulty PCM
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "ISC actuator duty" parameter on the scantool.
Service standard
A/CON switch OFF : 25~45%
A/CON switch ON : 35~55%
Page 279 of 353

damage.

POWER CIRCUIT INSPECITON
1. Ignition "OFF"
2. Disconnect ISCA connector.
Short circuit to chassis ground between ISCA harness connector and control relay.
Open circuit between ISCA harness connector and control relay.
1. In case,when ISCA connector is disconnected, the voltage of ISCA terminal 2 is

0V.
Possible cause: Open or short circuit in battery power line after fuse (15A INJ).
2. PCM also sets P1505 and P1507 if it detects the open circuit in ISCA power line.

Page 280 of 353
(1) Ignition "OFF"
(2) Disconnect ISCA connector.
(4) Measure voltage between terminal 1 , 3 of sensor harness connector and chassis ground.
Open or Short circuit to chassis ground between ISCA harness connector and PCM harness connector.
(1) Ignition "OFF"
(2) Disconnect ISCA connector and PCM connector.
(4) Measure resistance between terminal 1 , 3 of sensor harness connector and chassis ground.
Go to "Check for short between open coil and close coil harness " as below.
Short circuit to chassis ground between ISCA harness connector and PCM harness connector.
Page 281 of 353
3. Check for short between open coil and close coil harness
(1) Ignition "OFF"
(4) Measure resistance between terminal 1,3 of sensor harness connector.
Shorted circuit between ISCA open signal circuit and close signal circuit.
1. Check ISCA
Go to "Check for ISCA sticking " as below.
Substitute with a known-good ISCA and check for proper operation. If the problem is corrected, replace
ISCA and then go to "Verification of Vehicle Repair" procedure.
Page 282 of 353
2. Check for ISCA sticking.
(1) Ignition "OFF"
(2) Check that ISCA actuator valve is clean and not sticking.
(3) Check that throttle lever return spring is clean and sticking.
(4) Check intake air system and vacuum hoses to intake air system.
(5) Are the results of these checks OK?

SCHEMATIC DIAGRAM
Page 283 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring Strategy ● Rationality check, high
● Eng speed - desired eng speed : < -100 rpm
Threshold value
● Fuel cut - off : > 2 times ● Air leak in intake system
● Vacuum hose and PCV
● Vehicle speed = 0 ● Accelrator cable adjussted
● Coolant temperature > 75 degC(167 °F) improperly
● Intake air temperature > 9.75 degC(49.55 °F) ● faulty ISCA
Enable Conditions
● Altitude (model) < 2500 m ● faulty TPS
● I-controller > 14.8 % ● faulty PCSV
● Idle control enabled ● Faulty PCM
Fail Safe ● None
MONITOR DTC STATUS

Page 284 of 353
3. Monitor the "ISC actuator duty" parameter on the scantool.
Service standard

damage.

1. Ignition "OFF"
2. Disconnect ISCA connector.
3. .Ignition "ON" & Engine "OFF"
Page 285 of 353

0V.
2. ECM also sets P1505 and P1507 if it detects the open circuit in ISCA power line.

(1) Ignition "OFF"
(2) Disconnect ISCA connector.
(4) Measure voltage between terminal 1 , 3 of sensor harness connector and chassis ground.
Page 286 of 353
(1) Ignition "OFF"
(4) Measure resistance between terminal 1 , 3 of sensor harness connector and chassis ground.
(1) Ignition "OFF"
Page 287 of 353
1. Check ISCA
Go to "Check for ISCA sticking " as below.
2. Check for ISCA sticking.
(1) Ignition "OFF"
(2) Check that ISCA actuator valve is clean and not sticking.
(3) Check that throttle lever return spring is clean and sticking.
(4) Check intake air system and vacuum hoses to intake air system.
(5) Are the results of these checks OK?

SCHEMATIC DIAGRAM
Page 288 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 289 of 353
Monitoring
● Internal control module check
Strategy
Threshold
● Check sum fault(ROM)
value
Enable ● PCM H/W modification ● Faulty PCM
Conditions required
Diagnostic
● Once / drving
Time
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "CURRENT DATA" parameter on the scantool.

damage.

Page 290 of 353
1. Check for open in harness at Memory power input
(1) Ignition "OFF"
(2) Connect PCM connector.
(4) Measure voltage between terminal 12 of PCM harness connector and chassis ground.
Go to "Component Inspection" procedure
Open or short circuit to chassis ground between PCM harness connector and Control relay ON input
circuit.
1. Check PCM

SCHEMATIC DIAGRAM

COMPONENT LOCATION
Page 291 of 353
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring
● Rationality check
Strategy
● Signal at vehicle standstill is alternated : > ● Poor connections
Threshold value ● Faulty acceleration sensor
3 times
● High resistance in ground
Enable Conditions
● Faulty PCM
Fail Safe ● None
WAVEFORM INSPECTION
1. Engine "ON"
2. Monitor wave form at the terminal 3 of Acceleration sensor.
Page 292 of 353
corrosion, contamination,deterioration, or damage. Repair or replace as necessary and then go to "Verification of

damage.

1. Ignition "OFF"
2. Disconnect Acceleration sensor connector.
Short circuit to chassis ground between Acceleration sensor harness connector and reference voltage.
Open circuit between Acceleration sensor harness connector and PCM connector.
In case,when acceleration sensor connector is disconnected,the voltage at terminal 1 is 0V.

Possible cause: Open or short circuit in harness between terminal 32 of PCM and terminal 1 of
acceleration sensor or PCM

Page 293 of 353
(1) Ignition "OFF"
(2) Disconnect Acceleration sensor connector.
Open circuit or short circuit to chassis ground between Acceleration sensor harness connector and signal
circuit.
Open circuit between Acceleration sensor harness connector and PCM harness connector.


(1) Ignition "OFF"
(2) Disconnect Acceleration sensor connector and PCM connector.
Page 294 of 353
circuit.


1. Ignition "OFF"
Substitute with a known-good Acceleration sensor and check for proper operation. If the problem is
corrected, replace Acceleration sensor and then go to "Verification of Vehicle Repair" procedure.
In case,when acceleration sensor connector is disconnected,the resistance at terminal 2 is infinite.

Possible cause: Open in ground circuit between terminal 17 of PCM and terminal 2 of acceleration
sensor.

Page 295 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
Page 296 of 353
DTC DESCRIPTION

Monitoring
● Signal check, Low
Strategy ● Short to ground in signal
Threshold value ● Voltage : < 1.5V circuit (pin 60 to 17)
● Open in power circuit (pin
Enable
32)
Conditions
● Faulty Acceleration sensor
Diagnostic Time ● Continuous ● Faulty PCM
Fail Safe ● None
WAVEFORM INSPECTION
1. Engine "ON"

damage.
Page 297 of 353

1. Ignition "OFF"
Short circuit to chassis ground between Acceleration sensor harness connector and reference voltage.
Open circuit between Acceleration sensor harness connector and PCM connector.


(1) Ignition "OFF"
Page 298 of 353
circuit.


SCHEMATIC DIAGRAM
Page 299 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Monitoring ● Open in signal circuit
● Signal check, High
Strategy ● Short to battery in signal
Threshold value ● Voltage : > 3.5V circuit (pin 60 to 32)
Enable
● Poor connection of
Conditions
Acceleration sensor
Diagnostic Time ● Continuous ● Faulty Acceleration sensor
WAVEFORM INSPECTION
1. Engine "ON"
Page 300 of 353

damage.

Page 301 of 353
(1) Ignition "OFF"
(2) Disconnect Acceleration sensor connector.
circuit.


(1) Ignition "OFF"
Page 302 of 353

When the terminal 1 and 3 are shorted ,the resistance measured is below
1Ω.

1. Ignition "OFF"
In case,when acceleration sensor connector is disconnected,the resistance at terminal 2 is infinite.

Possible cause: Open in ground circuit between terminal 17 of PCM and terminal 2 of acceleration
sensor.


Page 303 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 304 of 353
Monitoring Strategy
Threshold value ● Shorted to GND / Disconnected
● Open in battery circuit
Enable Conditions ● Open circuit ● Open in control circuit
Diagnostic Time ● Continous ● Short to ground in control circuit
● Faulty ISCA
● The limp home value of ISCA depends on ● Faulty PCM
Fail Safe engine speed and throttle angle.
-PCM controls with mapping data.
MONITOR DTC STATUS

3. Monitor the "ISCA signal" parameter on the scantool.
Service standard

damage.
Page 305 of 353

1. Ignition "OFF"
2. Disconnect ISCA sensor connector.

0V.

Page 306 of 353
(1) Ignition "OFF"
(2) Disconnect ISCA sensor connector.
(1) Ignition "OFF"
(2) Disconnect ISCA sensor connector and PCM connector.
Page 307 of 353
(1) Ignition "OFF"
1. Check ISCA

Page 308 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
Page 309 of 353
DTC DESCRIPTION

Monitoring Strategy ● Circuit continuty check (opening coil)
Enable Conditions ● Shorted circuit ● Short to battery in control circuit
● Faulty ISCA
● Faulty PCM
● The limp home value of ISCA depends on
MONITOR DTC STATUS

Service standard

Page 310 of 353
damage.

1. Check for short between power and control harness
(1) Ignition "OFF"
Check for short to battery in control harness.

In case,when the ISCA connector is disconnected,the voltage of ISCA terminal 3 is 12

V.
Possible cause: Short circuit in battery power line after fuse (15A INJ).
Page 311 of 353
1. Check ISCA

SCHEMATIC DIAGRAM
Page 312 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 313 of 353
Monitoring Strategy
Threshold value ● Shorted to GND / Disconnected
● Open in battery circuit
Enable Conditions ● Open circuit ● Open in control circuit
Diagnostic Time ● Continous ● Short to ground in control circuit
● Faulty ISCA
● The limp home value of ISCA depends on ● Faulty PCM
MONITOR DTC STATUS

Service standard

damage.
Page 314 of 353

1. Ignition "OFF"
2. Disconnect ISCA sensor connector.

0V.

Page 315 of 353
(1) Ignition "OFF"
(1) Ignition "OFF"
Page 316 of 353
(1) Ignition "OFF"
1. Check ISCA

Page 317 of 353
SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
Page 318 of 353
DTC DESCRIPTION

Monitoring Strategy ● Circuit continuty check (opening coil)
Enable Conditions ● Shorted circuit ● Short to battery in control circuit
● Faulty ISCA
● Faulty PCM
● The limp home value of ISCA depends on
MONITOR DTC STATUS

Service standard

Page 319 of 353
damage.

1. Check for short between power and control harness
(1) Ignition "OFF"
Check for short to battery in control harness.

In case,when the ISCA connector is disconnected,the voltage of ISCA terminal 3 is 12

V.
Possible cause: Short circuit in battery power line after fuse (15A INJ).
Page 320 of 353
1. Check ISCA

SCHEMATIC DIAGRAM
Page 321 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 322 of 353
Monitoring Strategy ● Circuit continuity check
● Open in battery and control circuit
Threshold value ● Short to GND or disconnected
● Short to ground in control circuit
Enable Conditions ● Cooling fan control enabled (pin 50 to GND)
Diagnostic Time ● Faulty FAN Relay
● Faulty PCM
Fail Safe
MONITOR DTC STATUS

3. Monitor the "COOLING FAN" parameter on the scantool.
Service standard

damage.
Page 323 of 353

(1) Ignition "OFF"
(2) Disconnect RAD FAN Relay.
(4) Measure voltage between terminal 1 and 5 of RAD FAN Relay harness connector and chassis ground.
Open circuit or short circuit to chassis ground between RAD FAN Relay harness connector and ECU #1
Fuse 10A.
(1) Ignition "OFF"
(4) Measure voltage between terminal 3 of RAD FAN Relay harness connector and chassis ground.
Page 324 of 353

In case,when RAD FAN Relay connector is disconnected,the voltage at terminal 3 is 0V.

Possible cause : Short to ground in control circuit
1. Check RAD FAN Relay
(1) Ignition "OFF"
(3) Measure resistance between terminal 3 and 5 of RAD FAN Relay connector(To sensor side)
Substitute with a known-good RAD FAN Relay heater and check for proper operation. If the problem is
corrected, replace RAD FAN Relay and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 325 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 326 of 353
Monitoring
● Circuit continuity check
Strategy
Threshold value ● Short to battery ● Short to battery in control
circuit
Enable
● Cooling fan control enabled ● Faulty FAN Relay
Conditions
● Faulty PCM
MONITOR DTC STATUS

3. Monitor the "COOLING FAN" parameter on the scantool.
Service standard

damage.
Page 327 of 353

(1) Ignition "OFF"
(4) Measure voltage between terminal 3 of RAD FAN Relay harness connector and chassis ground.

In case,when RAD FAN Relay connector is disconnected,the voltage at terminal 3 is 0V.

Page 328 of 353
1. Check RAD FAN Relay
(1) Ignition "OFF"
(3) Measure resistance between terminal 3 and 5 of RAD FAN Relay connector(To sensor side)
Substitute with a known-good RAD FAN Relay heater and check for proper operation. If the problem is
corrected, replace RAD FAN Relay and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 329 of 353

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 330 of 353
Monitoring Strategy ● Signal check
● Duty cycle from TCU < 12.5 % or >99.6
Threshold value
%
● Contact resistance in connectors
Enable Conditions ● Torque reduction status enabled ● Faulty PCM
Fail Safe
MONITOR SCANTOOL DATA


damage.
Go to ""Component Inspection" procedure.
Page 331 of 353
1. Check PCM

SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

DTC Strategy ● Shift rate
● Engine speed 1600-3000 rpm ● Contact resistance in connections.
Enable Conditions ● Exhaust System
● Engine load 25-75 %
● Faulty Catalytic converter
● The second controller by downstream O2 ● Faulty HO2S(B1/S2)
Threshold Value
sensor> 1.2 s ● Faulty PCM
Diagnostic Time
Page 332 of 353

3. Monitor the HO2S(B1/S2) parameter on the scantool.

damage.
SYSTEM INSPECTION
Page 333 of 353
1. Check Exhaust System Inspection
(1) Visually/physically inspect the following conditions:
Exhaust system between HO2S(B1/S2) and Three way catalyst for air leakage
Damage, and for loose or missing hardware:
(2) Was a problem found in any of the above areas?
1. Check HO2S(B1/S1)
(1) Ignition "OFF"
(2) Remove HO2S(B1/S1)
(3) Visually/physically inspect following items:
Inspect the HO2S(B1/S1) for any silicon contamination. This contamination will be indicated by a white
powdery coating and this will result in a but false voltage signal
If contamination is evident on the HO2S(B1/S1), replace contaminated sensor
Go to "Check PCM" as below

2. Check PCM
(1) Ignition "OFF"
(4) Simulate voltage at terminal 2 of HO2S(B1/S2) sensor signal connector.
Page 334 of 353
(5) Is HO2S(B1/S2) signal value changed according to simulation voltage ?

SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 335 of 353
DTC Strategy ● Shift rate
● Engine speed 1600-3000 rpm ● Contact resistance in connections.
Enable Conditions ● Exhaust System
● Engine load 25-75 %
● Faulty Catalytic converter
● Second lambda controller from downstream ● Faulty HO2S(B1/S2)
Threshold Value
lambda control < -1.2 s ● Faulty PCM
Diagnostic Time

3. Monitor the HO2S(B1/S2) parameter on the scantool.

damage.

Page 336 of 353
SYSTEM INSPECTION
1. Check Exhaust System Inspection
(1) Visually/physically inspect the following conditions:
Exhaust system between HO2S(B1/S2) and Three way catalyst for air leakage
Damage, and for loose or missing hardware:
1. Check HO2S(B1/S1)
(1) Ignition "OFF"
(2) Remove HO2S(B1/S1)
(3) Visually/physically inspect following items:
Inspect the HO2S(B1/S1) for any silicon contamination. This contamination will be indicated by a white
powdery coating and this will result in a but false voltage signal
If contamination is evident on the HO2S(B1/S1), replace contaminated sensor
Go to "Check PCM" as below

2. Check PCM
(1) Ignition "OFF"
(4) Simulate voltage at terminal 2 of HO2S(B1/S2) sensor signal connector.
Page 337 of 353
(5) Is HO2S(B1/S2) signal value changed according to simulation voltage ?

SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 338 of 353
Monitoring
● Fuel trim limit
Strategy
Threshold value ● Additive long term value : > 10%
● Coolant temperature > 70 degC(158
°F) ● Faulty ignition system.
● Intake air temperature < 80 degC(176 ● EVAP PCSV malfunction.
°F) ● Faulty fuel injectors.
Enable ● Throttle angle < 60 % ● Leak in exhaust system.
Conditions ● Integrated air mass > 10 grams ● Faulty MAP,TPS,ECTS.
● Closed loop control enabled ● Faulty front HO2S.
● No transient control phase ● Faulty PCM
● No canister purge phase
● Air mass < 24 kg/h
Fail Safe ● None
MONITOR DTC STATUS

3. Monitor the "FR HO2S signal" parameter on the scantool.
Service standard
For front HO2S
Page 339 of 353

damage.
SYSTEM INSPECTION
Go to "Check for Exhaust system " as below.

Page 340 of 353
(1) Check exhaust system for leaks, cracks, loose connection.(especially exhaust manifold, catalyst around rear
HO2S, etc)
(2) Is exhaust system okay?
Go to "Check for Intake system"as below.
moves.
(4) Are vacuum hoses and PCV OK?
Go to "Check for spark plug" as below.

Go to "Check for Fuel injector " as below.
Fauity spark plugs.

Page 341 of 353
3. Check for Fuel injector
(1) Check for fuel injector operation.
(2) Are fuel injectors working normal and dispensing proper volume?

SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 342 of 353
Monitoring
● Fuel trim limit
Strategy
Threshold value ● Additive long term value : < -10%
Enable ● Throttle angle < 60 % ● Leak in exhaust system.
Conditions ● Integrated air mass > 10 grams ● Faulty MAP,TPS,ECTS.
● Engine speed < 920 rpm
Fail Safe ● None
MONITOR DTC STATUS

Service standard
For front HO2S
Page 343 of 353

damage.
SYSTEM INSPECTION

Page 344 of 353
HO2S, etc)

(5) Is intake system OK?
moves.

Page 345 of 353

SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 346 of 353
Monitoring
● Fuel trim limit
Strategy
● Multiplicative long term value 1,2 : >
Threshold value
1.23
● Throttle angle < 60 % ● Leak in exhaust system.
Enable
● Integrated air mass > 10 grams ● Faulty MAP,TPS,ECTS.
Conditions
● Air mass1 40-80 kg/h
● Air mass2 > 100 kg/h
Fail Safe ● None
MONITOR DTC STATUS

Service standard
For front HO2S
Page 347 of 353

damage.
SYSTEM INSPECTION

Page 348 of 353
HO2S, etc)
moves.

Go to "Check for Fuel injector " as below.
Fauity spark plugs.

Page 349 of 353

SCHEMATIC DIAGRAM

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 350 of 353
Monitoring
● Fuel trim limit
Strategy
● Multiplicative long term value 1,2 : <
Threshold value
0.77
● Throttle angle < 60 % ● Leak in exhaust system.
Enable
● Integrated air mass > 10 grams ● Faulty MAP,TPS,ECTS.
Conditions
● Engine load1 30-55 %
● Engine load2 > 70 %
Fail Safe ● None
MONITOR DTC STATUS

Service standard
For front HO2S
Page 351 of 353

damage.
SYSTEM INSPECTION

Page 352 of 353
HO2S, etc)

(5) Is intake system OK?
moves.

vRepair as necessary and then go to "Verification of Vehicle Repair" procedure.
Page 353 of 353

SCHEMATIC DIAGRAM
Page 1 of 53
ACCENT(LC) > 2005 > G 1.5 SOHC > Heating,Ventilation, Air Condioning
Heating,Ventilation, Air Condioning > General Information > Flow Diagram

REFRIGERATION CYCLE
Heating,Ventilation, Air Condioning > General Information > General Safety Information and Caution
Page 2 of 53
PRECAUTIONS
The air conditioning system uses R-134a refrigerant and FD46XG (PAG) refrigerant oil, which are not compatible
with R-12 refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do not attempt to
use R-12 servicing equipment; damage to the air conditioning system or your servicing equipment will result.
• Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
• Be careful when connecting service equipment.
• Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming service.
R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with
compressed air.
• Compressed air mixed with R-134a forms a combustible vapor.

• The vapor can burn or explode causing serious injury.
• Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.
• Always disconnect the negative cable from the battery whenever replacing air conditioning parts.
• Keep moisture and dirt out of the system, When disconnecting any lines, plug or cap the fittings immediately; don
t remove the caps or plugs until just before you reconnect each line.
• Before connecting any hose or line, apply a few drops of refrigerant oil to the O-ring.
• When tightening or loosening a fitting, use a second wrench to support the matching fitting.
• When discharging the system, use a R-134a refrigerant recovery/recycling/charging station; don t release
refrigerant into the atmosphere.
Heating,Ventilation, Air Condioning > General Information > Special Service Tools
SPECIAL TOOLS
Tool (Number and
Illustration Use
name)
09455-34000 Removal of field coil
Bearing and gear puller
09977-34000 Removal of pressure plate

Pressure plate bolt
remover
09977-33700 Removal and installation of shaft

Shaft seal remover and seal
installer
09977-33800 Removal of snap ring

Snap ring remover
Page 3 of 53
Heating,Ventilation, Air Condioning > General Information > Troubleshooting

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause
of the problem. Check each part in order. If necessary, replace these parts.
STANDARD
Symptom Suspect Area Remedy
No blower operation 1. HTR Fuse Replace
2. Blower relay Replace
3. Blower motor Replace
4. Blower resistor Replace
5. Blower speed control switch Replace
6. Wire harness Replace
No air temperature control 1. Engine coolant capacity Add coolant

2. Heater control assembly Replace
No compressor operation 1. Refrigerant capacity Add refrigerant
2. A/C Fuse Replace
3. Magnetic clutch Replace
4. Compressor Replace
5. Triple pressure switch Replace
6. A/C switch Replace
7. Thermistor Replace
No cool comes out 1. Refrigerant capacity Add refrigerant

2. Refrigerant pressure Apply a vacuum and add
3. Drive belt refrigerant
4. Magnetic clutch Adjust
Replace
5. Compressor
Replace
6. Triple pressure switch
Replace
7. Thermistor Replace
8. A/C switch Replace
9. Heater control assembly Replace
Insufficient cooling 1. Refrigerant capacity
Add refrigerant
2. Drive belt Adjust
3. Magnetic clutch Replace
4. Compressor Replace
5. Condenser Replace
6. Expansion valve Replace
7. Evaporator Replace
8. Refrigerant lines Replace
9. Triple pressure switch Replace
Page 4 of 53
9. Triple pressure switch
Replace
10. Heater control assembly
No engine idle-up when A/C switch 1. Engine (and ECT) ECU -
ON 2. Wire harness Replace
No air inlet control Heater control assembly, cable, door Replace
No mode control Heater control assembly, cable, door Replace
No condenser fan operation 1. ECU-IG Fuse Replace
2. Fan motor Replace
3. Engine (and ECT) ECU -
Heating,Ventilation, Air Condioning > General Information > Repair procedures

This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure
when the these conditions are established.
TEST CONDITIONS
• Temperature at the air inlet with the switch set at RECIRC is 30~35°C (86~95°F)
• Engine running at 1,500rpm
• Blower speed control knob on "4" position
• Temperature control knob on "COOL" position
It should be noted that the gauge indications may vary slightly due to ambient temperature conditions.
1. Normally functioning refrigeration system.
Gauge reading :
Low pressure side :
0.15~0.25 MPa (21.8~36.3 psi, 1.5~2.5 kgf/cm²)
High pressure side :
1.37~1.57 MPa (199~228 psi, 14~16 kgf/cm²)
Page 5 of 53
2. Moisture present in refrigeration system.
Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system
During operation, pressure Moisture entered in • Drier in oversaturected - Raplace drier
on low pressure side refrigeration system freezes state - Remove moisture in
sometimes become a at expansion valve orifice • Moisture in refrigeration cycle through repeatedly
vacuum and sometime and temporarily stops system freezes at evacuating air
normal cycle, but normal state is expansion valve orifice - Charge proper amount
restored after a time when and block circulation of of new refrigerant
the ice melts refrigerant
3. Insufficient cooling
Symptom seen in
• Pressure low on both Gas leakage at some place • Insufficient refrigerant in - Check for gas leakage
low and high pressure in refrigeration system system with gas leak detector
sides • Refrigerant leaking and repair if necessary
• Insufficient cooling - Charge proper amount
performance of refrigerant
- If indicated pressure
value is near 0 when
connected to gauge,
create the vacuum after
inspecting and repairing
the location of the leak
Page 6 of 53
4. Poor circulation of refrigerant
Symptom seen in
• Pressure low in both low Refrigerant flow obstructed Condenser clogged Replace drier
and high pressure sides by dirt in drier
• Frost on tube from
receiver to unit
5. Refrigerant does not circulate
Symptom seen in
• Vacuum indicated on • Refrigerant flow Refrigerant does not - Check expansion valve
low pressure side, very obstructed by moisture circulate - Clean out dirt in
low pressure indicated or dirt in refrigeration expansion valve by
on high pressure side system blowing with air
• Frost or dew seen on • Refrigerant flow - Replace drier
piping before and after obstructed by gas - Evacuate air and charge
receiver/drier or leakage from expansion new refrigerant to
expansion valve valve proper amount
- For gas leakage from
expansion valve, replace
expansion valve
Page 7 of 53
6. Refrigerant overcharged or insufficient cooling of condenser
Symptom seen in
Press too high on both low • Unable to develop • Excessive refrigerant in - (1) Clean condenser
and high pressure sides sufficient performance cycle → refrigerant - (2) Check cooling fan
due to excessive overcharged with fluid coupling
• Insufficient cooling of • Condenser cooling → operation.
condenser condenser fins clogged - (3) If (1) and (2) are in
or condenser fan faulty normal state, check
amount of refrigerant
Charge proper amount
of refrigerant
7. Air present in refrigeration system
Symptom seen in
• Press too high on both Air entered in refrigeration • Air present in - Check compressor oil
low and high pressure system refrigeration system to see if it is see if it is
sides • Insufficient vacuum dirty or insufficient
• The low pressure piping purging - Evacuate air and charge
hot to the touch new refrigerant
Page 8 of 53
8. Expansion valve improperly
Symptom seen in
• Pressure too high on Trouble in expansion valve • Excessive refrigerant in - Check expansion valve
both low and high low pressure piping - Replace if defective
pressure sides • Expansion valve opened
• Frost or large amount of too wide
dew on piping on low
pressure side
9. Defective compression compressor
Symptom seen in
• Pressure too high on low Internal leak in compressor • Compression defective Repair or replace
high pressure sides • Valve leaking or broken compressor
• Pressure too low to on sliding parts
high pressure side
INSPECT FOR LEAKAGE OF REFRIGERANT

Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when
conducting service operations which are accompanied by disassembly or loosening or connection fittings.
In order to use the leak detector properly, read the manual supplied by the manufacturer.
Page 9 of 53
1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage
with a leak detector.
2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect
the fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.
A/C SYSTEM TESTS
• Compressed air mixed with R-134a forms a combustible vapor.

• The vapor can burn or explode causing serious injury.
• Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.
1. Connect a R-134a refrigerant recover/recycling/charging station to the high-pressure service port and the low-
pressure service port, following the equipment manufacturer s instructions.
2. Insert a thermometer in the center vent.
Determine the relative humidity and air temperature.
3. Test conditions :
A. Avoid direct sunlight.
B. Open the hood.
C. Open the front doors.
D. Set the temperature control dial on MAX COOL, the mode control switch on VENT and the recirculation
control switch on RECIRCULATE.
E. Turn the A/C switch on and the fan switch on MAX.
F. Run the engine at 1,500 rpm.
G. No driver or passengers in vehicle.
Page 10 of 53
4. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature
from the thermometer in the dash vent, the intake temperature near the blower unit behind the glove box and the
high and low system pressure from the A/C gauges.
REFRIGERANT RECOVERY
1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and
the low-pressure service port (C), as shown, following the equipment manufacturer s instruction.
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be
sure to put the same amount of new refrigerant oil back into the A/C system before charging.
SYSTEM EVACUATION
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be
evacuated using a R-134a refrigerant recover/recycling/charging station (If the system has been open for several
days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)
2. Connect a R-134a refrigerant recovery/recycling/charging station(A) to the high-pressure service port(B) and the
low-pressure service port(C), as shown, following the equipment manufacturer s instruction. Evacuate the system.
3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably
a leak in the system. Partially charge the system, and check for leaks.
SYSTEM CHARGING
Page 11 of 53
1. Connect a R-134a refrigerant recover/recycling/charging station (A) to the high-pressure service port (B) and the
low-pressure service port (C), as shown, following the equipment manufacture s instructions.
2. Add the same amount of new refrigerant oil to the system that was removed during recovery.
3. Carge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the
compressor will be damaged.
Refrigerant capacity :
Select the appropriate units of measure for your charging station : 550 ± 25g
Heating,Ventilation, Air Condioning > General Information > Specifications

SPECIFICATIONS
Item Specification
Heating Heater
- Type Air mix type
- Capacity (Kcal/h) 4,500 ± 10%
Air Evaporator
conditioning - Cooling capacity 4,100 ± 10%
(Kcal/h)
Compressor
- Type
Swash plate (HS-15)
- Lubricating oil
FD46XG (PAG)
- Oil capacity (cc)
180 ± 10
- Piston displacement 154
(cc/rev)
Pressure relief valve Working pressure : 35.0 ~ 42.2
(kgf/cm²) Resealed pressure : Min. 28.1
Magnetic clutch
- Pulley pitch dia ø125
- Valtage & wattage D.C 12.8V, Max, 54W
- Torque Min. 4.4kg·m
Page 12 of 53
Condenser
- Heat capacity (Kcal/h) A/T : 11,800 ± 5%
M/T 1.6 DOHC : 11,800 ± 5%
M/T 1.5 SOHC : 9,400 ± 5%
Refrigerant&capacity R-134a (550 ± 25g)
Triple pressure switch High pressure
(kgf/cm²) - ON 32.0 ± 2.0
- OFF 26.0 ± 2.0
Middle pressure
- ON 18.0 ± 0.8
- OFF 14.0 ± 1.2
Low pressure
- ON 23 +0.25/-0.29
- OFF 2.0 ± 0.2
Expansion valve
- Super heat value 1.5 at 0°C
(kgf/cm²) 2.2 at 10°C
Thermostat OFF 1.5 ± 0.6°C
ON 3.0 ± 0.6°C
Heater control assembly Rotary Cable Type
Heating,Ventilation, Air Condioning > Air conditioning System > Drive belt > Repair procedures
ADJUSTMENT
INSPECTION (GASOLINE)
Deflection :
Used belt : 6.0~7.0mm (0.24~0.28 in.)
New belt : 5.0~5.5mm (0.20~0.22 in.)
These items when adjusting belt tension :

• If there are cracks or any damage evident on the belt, replace it with a new one.
• "Used belt" means a belt which has been used for five minutes or more.
• "New belt" means a belt which has been used for less than five minutes.
Page 13 of 53
ADJUSTMENT
1. Loosen the tension mounting bolt(B).
2. Turn the adjusting bolt(C) to obtain the proper belt tension, then retighten the mounting bolt.
3. Recheck the deflection of the A/C compressor belt.
Heating,Ventilation, Air Condioning > Air conditioning System > Compressor > Description and
Operation
OPERATION
MAGNETIC CLUTCH
Heating,Ventilation, Air Condioning > Air conditioning System > Compressor > Components and
Components Location
COMPONENT LOCATION
Page 14 of 53
COMPONENTS
Page 15 of 53
Page 16 of 53
Heating,Ventilation, Air Condioning > Air conditioning System > Compressor > Repair procedures
REMOVAL
1. Discharge the refrigerant.
Page 17 of 53
2. Remove the tension bolt.
3. Remove the drive-belt.
4. Remove the suction hose and discharge hose from the compressor.
5. Remove the 4 mounting bolts on the compressor.
6. Remove the compressor downwards.
INSTALLATION
1. Tighten the 4 compressor mounting bolts.
2. Connect the suction hose and discharge hose to the compressor.

Page 18 of 53
3. Connect the drive-belt.
4. Adjust the drive-belt tension.

Item Deflection L (mm)
New one 5~5.5
Used one 6~7
After driving 8
5. Supply the coolant.
Specified amount : 550 ± 25g
DISASSEMBLY
CLUTCH HUB AND PULLEY
Page 19 of 53
1. Remove the clutch hub supporting bolt using a spanner wrench.
2. Pull out the clutch hub and shim from the compressor shaft. If it is hard to pull out, insert a 8mm bolt into the shaft
hole to remove the hub from the shaft.
3. Remove the pulley supporting the snap ring.
4. Remove the pulley and bearing assembly from the compressor.
CLUTCH FIELD COIL

1. Remove the clutch hub and pulley.
2. Install a shaft protection tool at the compressor opening.
3. Install the pulley at the compressor.
Place the puller screw end at the shaft protectors center concave and the puller projection around the rear side
field coil.
Page 20 of 53
4. Turn the puller screw using a wrench and remove the coil.
Do not use air tools.
SHAFT SEAL
Prior to replacement of the compressor shaft, remove the compressor from the vehicle and discharge the refrigerant.
1. Remove the clutch hub from the compressor.
2. Remove the shaft seal felt from the nose of the compressor with a pick type tool.
3. Blow any debris from inside the compressor nose with low pressure compressed air. Then, clean the inside and
outside nose area of the compressor with a lint-free cloth to remove any oil and dirt.
4. Using a snap ring remover, remove the shaft seal support snap ring out of the compressor nose.
(1) Insert tip of the snap ring remover into one of the snap ring eyes (View A).
(2) Rotate the snap ring remover to position the tool tip and snap ring eye closest to the compressor shaft (View
B).
(3) Pull the snap ring remover tool up quickly while keeping the tool shaft against the side of the nose opening to
remove the snap ring (View C).
5. Position the shaft seal remover tool (09977-33700) over the compressor shaft and push the tool into the nose of the
compressor and down against the shaft seal. Engage the end of the tool with the internal diameter of the shaft seal.
While holding the hex part of the tool, turn the tool handle clockwise to expand the tool tip inside the seal inner
radius. Then, pull the shaft seal from the compressor with the tool
Page 21 of 53
REASSEMBLY
SHAFT SEAL
1. Obtain a new shaft seal kit. Carefully remove the contents from the package and locate the plastic shaft seal
protector. Inspect the protector for any burrs or other damage. Do not use the protector if it is damaged. Obtain
another shaft seal kit and use the protector from it.
2. Using a clean lint-free cloth, clean the shaft and the seal pocket inside the compressor nose.
3. Dip the shaft seal protector and seal in clean refrigerant oil and position the seal on the protector with the lip of
the seal pointing toward the large end of the protector.
Page 22 of 53
4. Place the seal protector with shaft seal over the end of the compressor shaft.
5. Place the shaft seal installer tool over the end of the shaft seal protector. Then, slowly push the shaft seal down
the protector until it is seated in the compressor.
6. Remove the seal installer and seat protector from the compressor.
7. Place a new seal retaining snap ring into the compressor nose opening and seat the snap ring into the groove with
the remover tool.
8. Leak test the shaft seal installation after rotating the shaft about 10 revolutions with the clutch hub.
9. Install a new felt into the compressor nose.
10. Install the clutch hub on the compressor as outlined in this section.
CLUTCH FIELD COIL
1. Clean the front head coil mounting portion.
2. Place the compressor vertically and put the coil in position of compressor front head.
Check the electric connector of clutch coil is located in position.
3. Place the coil compression tool in the compressor nose and the center of field coil.
4. Place two 8 inch pullers on the compressor and compression tool. The jaws of puller should deeply hold the front
mounting portion of compressor, then the screw should be located in the central position of the compression tool.
5. Using a wrench, tighten the screw so as to securely seat the coil on the compressor front head.
6. Install the clutch pulley and hub on the compressor.
CLUTCH HUB AND PULLEY

1. Clean the pulley bearing surface of the compressor head and remove dirt and rust.
Page 23 of 53
2. Install the pulley and bearing on the compressor.
3. Install the snap ring with the bevelled side facing outward.
4. Place shim of specified side at the hub spline opening inside and slide the hub onto the compressor shaft end.
5. Install a new hub supporting bolt on the compressor shaft end. Tighten the bolt to the specified torque.
Tightening torque : 110~140kgf·cm
Do not use air tools.
INSPECTION
1. Check the plated parts of the pressure plate for color changes, peeling or other damage. If there is damage,
replace the clutch set.
Page 24 of 53
2. Check the pulley bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it
is noisy or has excessive play/drag.
3. Measure the clearance between the pulley (A) and the pressure plate (B) all the way around. If the clearance is
not within specified limits, remove the pressure plate and add or remove shims as needed to increase or decrease
clearance.
Clearance : 0.35 ~ 0.75mm (0.0138 ~ 0.0295 in.)
The shims are available in seven thicknesses : 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm and
1.3mm.
4. Check operating of the magnetic clutch.

Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the
compressor body.
Check the magnetic clutch operating noise to determine the condition.
Heating,Ventilation, Air Condioning > Air conditioning System > Condenser > Components and
Components Location
COMPONENTS
Page 25 of 53
Heating,Ventilation, Air Condioning > Air conditioning System > Condenser > Repair procedures
REMOVAL
Page 26 of 53
1. Remove the cooling module connector.
2. Remove the cooling module (condenser fan).

3. Remove the liquid tube nut.
4. Remove the condenser mounting bolts (2).
Tightening torque:
8~12Nm (80~120kfg·cm, 5.9~8.9lbf·ft)
5. Remove the condenser upward by pressing the radiator backward the vehicle.
INSTALLATION
Installation is the reverse of removal.
INSPECTION
1. Check condenser pin for clogging and damage. If clogged, clean it with water, and blow it with compressed air.
If bent, gently stretch it using a screwdriver or pliers.
2. Check the condenser connection area for leakage, and repair or replace if required.
Heating,Ventilation, Air Condioning > Air conditioning System > Receiver/Drier > Repair procedures
REPLACEMENT
Page 27 of 53
1. Remove the condenser, and then remove the bottom cap (B) from the receiver/drier tank (A).
Use of impact wrench may cause cracking on the receiver/drier tank connecting pipe to the
condenser.
2. Remove the desiccant from the receiver/drier tank using a long nose plier.
3. Check for crumbled desiccant and clogged bottom cap filter.
4. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
5. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed
to air for use.
6. Install the new bottom cap to the receiver drier tank.
Tightening torque :
20~25Nm (2.0~2.5kgf·m, 14.5~18.2 lbf·ft)
Always replace the desiccant and bottom cap at the same time.
Heating,Ventilation, Air Condioning > Air conditioning System > Triple pressure switch > Description
and Operation
DESCRIPTION
The triple switch is a combination of a middle switch as well as conventional low pressure and high pressure
switches. The low pressure switch will turn off to stop compressor operation if refrigerant pressure is low. The high
pressure switch will turn off to stop compressor operation if refrigerant pressure is too high. The middle switch will it
turn on at a medium level pressure to determine the A/C system is overheating. It will cool the A/C system by
operating the radiator fan and the condenser fan at high speed.
OPERATING CHARACTERISTIC (kgf/cm²)
Pressure ON OFF
High 32.0 ± 2.0 26.0 ± 2.0
2.3 + 0.25 /
Low 2.0 ± 0.2
-0.29
Middle 18.0 ± 0.8 14.0 ± 1.2
LOW & HIGH

Page 28 of 53
MIDDLE
Heating,Ventilation, Air Condioning > Air conditioning System > Evaporator unit > Components and
Components Location
COMPONENTS
Page 29 of 53
Heating,Ventilation, Air Condioning > Air conditioning System > Evaporator unit > Repair procedures
REMOVAL
1. Discharge the refrigerant.
Page 30 of 53
2. Remove the air conditioner suction hose, liquid tube and grommet.
3. Remove the 2 control cables of heater side and one control cable of blower side.
4. Remove the center facia panel from the lower portion.
5. Disconnect the switch connectors and remove the center facia panel.
6. Loosen the mounting bolts on the main crash pad and remove the main crash pad.
Page 31 of 53
7. Remove the evaporator core temp sensor (thermistor) connector.
8. Disconnect the blower resistor and blower motor connector.
9. Remove the evaporator assembly.
INSTALLATION
Page 32 of 53
DISASSEMBLY AND REASSEMBLY
Refer to "COMPONENTS".
Heating,Ventilation, Air Condioning > Heater > Heater Unit > Components and Components Location
COMPONENTS
Heating,Ventilation, Air Condioning > Heater > Heater Unit > Repair procedures
REMOVAL
Page 33 of 53
1. Disconnect the (-)negative battery terminal.
2. Drain the coolant of the radiator.
3. Remove the A/C suction hose, liquid tube and grommet.
4. Remove the 2 heater side control cables and one blower side control cable.
7. After removing the mounting bolts, remove the main crash pad. (Refter to "CRASH PAD" of BD group)
Page 34 of 53
8. Disconnect the evaporator core temp sensor (thermister), blower resistor connector, and blower motor
connector.
9. Remove the evaporator unit.
10. Remove the heater assembly.
INSTALLATION
Installation is the reverse of removal. (Prior to installation of temp. control and mode control cables, first install the
locating pin.)

Refer to "COMPONENTS" for disassembly and reassembly. When installing and reassembling the temp. control
and mode control cable, refer to the following chart.
Page 35 of 53
Lever load
Condition Temp. control Mode control
cable cable
Blower : 12V
Max 2.0kgf Max 2.0kgf
Mode : ALL
Heating,Ventilation, Air Condioning > Heater > The Other Heater Component > Components and
Components Location
COMPONENTS
Page 36 of 53
Heating,Ventilation, Air Condioning > Blower > Schematic Diagrams

SCHEMATIC DIAGRAM (MANUAL) (1)
Page 37 of 53

Page 38 of 53

Page 39 of 53
Heating,Ventilation, Air Condioning > Blower > Blower Unit > Components and Components Location
COMPONENTS
Page 40 of 53
Heating,Ventilation, Air Condioning > Blower > Blower Unit > Repair procedures
REMOVAL
Page 41 of 53
1. Remove the 2 heater side control cables and one blower side control cable.
4. After removing the mounting bolts, remove the main crash pad. (Refer to "CRASH PAD" of BD guoup)
5. Disconnect the evaporator core temp sensor (thermister), blower resistor connector, and motor connector.
Page 42 of 53
6. Remove the evaporator unit.
7. Remove the blower unit.
INSTALLATION
Installation is the reverse of removal. (Prior to installation of intake and exhaust cables, install the locating pin)

1. Loosen the motor mounting screw.
Page 43 of 53
2. Loosen the duct and blower case mounting screw.
3. Disconnect the door lever and arm.
4. Remove the blower resistor.
Heating,Ventilation, Air Condioning > Blower > Blower Motor > Repair procedures
INSPECTION
1. Check the blower motor shaft for bend.
2. Check the packing portion for crack.
3. Check the fan for damage.
4. Check the blower case for damage.
5. Check for the air selection damper operation.
6. Connect the blower motor to the battery and check for smooth operation.
7. Connect the blower motor to the opposite poles of battery and check for reverse operation.
Heating,Ventilation, Air Condioning > Blower > Blower Resistor > Repair procedures
INSPECTION
Measure the resistance between terminals and replace the blower resistor if the measured value is not within the
specified range.
Page 44 of 53
Heating,Ventilation, Air Condioning > Blower > Control Panel > Components and Components
Location
COMPONENTS
Page 45 of 53
Page 46 of 53
Heating,Ventilation, Air Condioning > Blower > Control Panel > Repair procedures
Page 47 of 53
1. Remove the 2 control cables in the heater side and one control cable in the blower side.

Refer to "COMPONENTS".
Heating,Ventilation, Air Condioning > Blower > Air cleaner filter > Repair procedures
REPLACEMENT
Page 48 of 53
1. Open the glove box, remove the glove box stopper in the lower crash pad (assist seat side), and completely
lower the glove box.
2. Disconnect the intake and exhaust cable from the blower unit.
3. Press the hook on the air conditioner side air filter cover and remove the cover.
Page 49 of 53
4. Replace the upper/lower air filters.
When removing and installing, don't forget there are 2 air filters in the air
conditioner.
Heating,Ventilation, Air Condioning > Troubleshooting > P0645

COMPONENT LOCATION
GENERAL DESCTIPTION
DTC DESCRIPTION

Page 50 of 53
Monitoring Strategy ● Circuit continuity check ● Open in battery and control circuit
Threshold value ● Short to GND or disconnected ● Short to ground in control circuit
(pin 69 to GND)
Enable Conditions ● Cooling fan control enabled
● Short to battery in control circuit
Diagnostic Time ● Faulty A/C Relay
Fail Safe ● Faulty PCM
MONITOR DTC STATUS

3. Monitor the "A/C Relay" parameter on the scantool.
The data shown above is only for reference and there may be a little difference
actually.
Service standard

damage.

Page 51 of 53
(1) Ignition "OFF"
(2) Disconnect A/C Relay.
(4) Measure voltage between terminal 1 and 5 of A/C Relay harness connector and chassis ground.
Open circuit or short circuit to chassis ground between A/C Relay harness connector and A/C FUSE 10A
1. Ignition "OFF"
2. Disconnect A/C Relay.
4. Measure voltage between terminal 3 of A/C Relay harness connector and chassis ground.
Page 52 of 53
Check for open or Short to battery in control circuit.

1. In case,when A/C Relay connector is disconnected,the voltage at terminal 3 is

12V.
Possible cause : Short to battery in control circuit
2. In case,when A/C Relay connector is disconnected,the voltage at terminal 3 is
0V.
1. Check A/C Relay
(1) Ignition "OFF"
(2) Disconnect A/C Relay.
(3) Measure resistance between terminal 3 and 5 of A/C Relay connector(To sensor side)
Substitute with a known-good A/C Relay heater and check for proper operation. If the problem is
corrected, replace A/C Relay and then go to "Verification of Vehicle Repair" procedure.

Page 53 of 53
SCHEMATIC DIAGRAM
Page 1 of 14
ACCENT(LC) > 2005 > G 1.5 SOHC > Manual Transaxle System
Manual Transaxle System > Manual Transaxle System > Components and Components Location
GENERAL INFORMATION (M5AF3)
Manual transaxle overhaul section has been separated from the shop manual.
M5AF3 overhaul section was included in the overhaul manual.
SECTION VIEW
Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Components and
Components Location
COMPONENTS (1)
Page 2 of 14
COMPONENTS (2)
Page 3 of 14
Manual Transaxle System > Manual Transaxle System > Manual Transaxle > Repair procedures
REMOVAL
Page 4 of 14
1. Remove the battery terminal and the battery.
2. Removal the air cleaner.
3. Remove the back-up lamp switch.
4. Remove the clutch release mounting bolts.

Page 5 of 14
5. Remove the cotter pin of the shift cable.
6. Remove the cotter pin of the selector cable.
7. Remove the clip of the shift cable.

8. Remove the clip of the selector cable.
9. Remove the speedometer driven gear connector.
10. Remove the u-joint.
11. Remove the power steering return hose.

12. Remove the tire.
Page 6 of 14
13. Remove the starter motor upward the transaxle.
14. Remove the bolt for the upper connection of the engine and the transaxle.
15. Remove the caliper after lifting up the vehicle.

Page 7 of 14
16. Separate the tie rod end from the pin and nut.
17. Remove the oil drain plug and drain the oil.
18. Remove the wheel speed sensor and the knuckle mounting bolt.
19. Remove the drive shaft and the hub nut.
20. Install the special tool, the engine support fixture on the engine assembly.
Page 8 of 14
21. Remove the transaxle mounting bracket after removing the hole cover and the mounting bolts.
22. Remove the front roll stopper.
24. Remove the front muffler.
25. Remove the bell housing cover. (Bolt : 5EA)

Page 9 of 14
26. Install the jack for supporting transaxle.
27. Remove the sub frame.

28. Remove the lower mounting bolts of the transaxle.
29. Remove the transaxle.
INSTALLATION
INSPECTION
TRANSAXLE GEAR OIL LEVEL INSPECTION
Inspect the transaxle for evidence of leakage. Check the gear oil level by removing the filler plug. If the oil is
contaminated, it is necessary to replace it with new oil.
1. Remove the oil filler plug and check the level with finger.
2. Oil level must be up to the filler hole. If it is below the hole, add oil until it runs out, then reinstall the plug.
3. Replace the oil if the transaxle gear oil is noticeably dirty, or it is not of a suitable viscosity.
REPLACEMENT OF TRANSAXLE GEAR OIL
Use HP Gear Oil SAE 75W/90 (API-GL-4)
1. With the vehicle parked on a level surface, remove the drain plug and drain the transaxle oil.
2. Replace the gasket with a new one and install the drain plug.
Tightening torque:
Drain plug:30~35 Nm (300~350 kg·cm, 22~25 lb·ft)
Page 10 of 14
3. Add new oil the through the filler plug, filling to the same level as the opening plug.
Transaxle oil total capacity:

2.15 Liters (2.27 U.s.qts., 1.89 lmp.qts.)
Tightening torque :
Filler plug:30~35 Nm (300~350 kg·cm, 22~25 lb·ft)
DRIVE SHAFT OIL SEAL REPLACEMENT

1. Disconnect the drive shaft from the transaxle (Refer to DS GROUP).
2. Using a flat-tip screwdriver, remove the oil seal.
3. Using the special tool (09431-21200), tap the drive shaft oil seal into the transaxle.
4. Apply a coating of gear oil to the lip of the oil seal.
Transaxle gear oil:

HYUNDAI GENUINE PARTS MTF 75W/90
conforming to API GL-4 or higher
Manual Transaxle System > Manual Transaxle System > Shift Lever > Components and Components
Location
COMPONENTS
Page 11 of 14
Manual Transaxle System > Manual Transaxle System > Shift Lever > Repair procedures
INSPECTION
1. Check the bushing for wear or damage.
2. Check the return spring for damage or deterioration.
REASSEMBLY
1. Apply multi-purpose grease to the sliding part of the bushings.
Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
Page 12 of 14
COMPONENTS
Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
Repair procedures
REMOVAL
Page 13 of 14
1. Remove the shift knob and the rear console.
2. Remove the front console.
3. Remove the cable mounting bolts of the lower dash board.
4. Remove the cotter pin of the shift cable.
5. Remove the cotter pin of the selector cable.

Page 14 of 14
6. Remove the clip of the shift cable and the selector cable.
7. Remove the shift lever assembly.
INSTALLATION
Installation is the reverse of the removal.
INSPECTION
1. Check the select cable for proper operation and for damage.
2. Check the shift cable for proper operation and for damage.
3. Check the boot for damage.
4. Check each bushing for wear, abrasion, sticking, restricted movement or damage.
5. Check for a weak or damaged spring.
Page 1 of 90
ACCENT(LC) > 2005 > G 1.5 SOHC > Restraint
Restraint > General Information > General Information

GENERAL
INFLATOR MODULE (DAB, PAB, SAB)
Page 2 of 90
1. When removing the airbag module or handling a new airbag module, it should be placed with the pad top surface
facing up. In this case, the twin-lock type connector lock lever should be in the locked state and care should be
taken to place it so the connecter will not be damaged. Do not store a steering wheel pad on top of another one.
(Storing the pad with its metallic surface up may lead to a serious accident if the airbag should inflate
accidentally.)
2. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very
dangerous.)
3. Store the airbag module where the ambient temperature remains below 93°C (200°F), without high humidity and
away from electrical noise.
4. During electric welding, disconnect the airbag under the steering column near the MULTI-FUNCTION
SWITCH connector before starting work.
DUAL STAGE AIRBAGS (DAB, PAB)
In a light crash, the first stage of the duel stage airbag is deployed, and the second stage is deployed in 127ms after
deployment of the first stage by SRSCM.
When scrapping a car of intentionally deploying the replaced airbag modules, deploy individual stage.
CUSTOMER CAUTIONS
1. Be sure to proceed with airbag related service only after approx. 30 seconds or longer from the time the ignition
switch is turned to the LOCK position and the negative (-) battery cable is disconnected from the battery. The
airbag system is equipped with a back-up power source to assure the deployment of airbags when the battery
cable is disconneted during an accident. The back-up power is available for approx. 150ms.
2. When the negative (-) battery cable is disconnected from the battery, the clock and audio system's memory will
be wiped out. So before starting work, make a record of the contents of the audio system's memory. When the
work is finished, reset the audio system and adjust the clock.
3. Symptoms of malfunction of the airbag system are difficult to detect, so the diagnostic codes become the most
important source of information when troubleshooting.
4. When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the battery.
5. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
6. Never attempt to disassemble and repair the airbag modules (DAB, PAB, SAB, BPT), clock spring and wiring in
order to reuse them.
7. If any component of the SRS has been dropped, or if there are cracks, dents or other defects in the case,
bracket or connector, replace them with new ones.
8. After work on the airbag system is completed, perform an SRS SRI check. The airbag indicator lamp can be
triggered by faults in other circuit in some cases. Therefore if the airbag indicator lamp goes on, be sure to erase
the DTC codes using the Hi-Scan Pro just after repairing or replacing the troubled parts, including the fuse.
9. Especially when performing body welding, never fail to disconnect the battery's negative (-) terminal.
Restraint > General Information > Special Service Tools

SPECIAL TOOLS
Page 3 of 90
Airbag deployment tool
0957A-34100A PAB : 0957A-25000 (Dual stage)
Deployment tool DAB, BPT : 0957A-38500
PAB, SAB : 0957A-38100
Simulator to check the resistance of each wiring harness

Dummy adapter
0957A-38200
PAB : 0957A-25100 (Dual stage)
Dummy
DAB, BPT : 0957A-1C000
PAB, SAB : 0957A-38300
0957A-25000
Use with deployment tool.
Deployment adapter
0957A-38500
Deployment adapter
0957A-38100
Deployment adapter
0957A-25100
Use with dummy.
Dummy adapter
0957A-1C000
Use with dummy
Dummy adapter
0957A-38300
Use with dummy
Dummy adapter
* DAB: Driver Airbag

* PAB: Passenger Airbag
* SAB: Side Airbag
* BPT: Belt Pretensioner
Restraint > Supplemental Restraint System Control Module (SRnodeM) > Schematic Diagrams
SRSCM CONNECTOR
DAB+PAB+SAB+BPT (SRE-LC)
Page 4 of 90
CONNECTOR
PIN NO. FUNCTION INPUT/OUTPUT
1 Passenger side airbag, High Output
2 Passenger side airbag, Low Output
3 Driver side airbag, Low Output
4 Driver side airbag, High Output
5 Battery supply Input
6 GND Input
7 Warning lamp Output
8 - -
9 K-diagnostic line Input/output
10 Driver airbag, High Output
11 Driver airbag, Low Output
12 - -
13 Passenger airbag, High Output
14 Passenger airbag, Low Output
15 - -
Passenger belt pretensioner,
16 Output
Low
17 Output
High
18 Driver belt pretensioner, High Output
19 Driver belt pretensioner, Low Output
20 Driver satellite sensor, High Output
21 Driver satellite sensor, Low Output
22 - -
23 - -
24 - -
25 - -
26 ~ 27 Shorting bar -
Page 5 of 90
30 - -
33 - -
34 Crash output Output
37 - -
40 - -
45 Driver satellite sensor, Low Output
46 Passenger satellite sensor, Low Output
47 - -
48 - -
49 - -
50 - -
DAB+PAB+SAB+BPT (DUAL-STAGE AIRBAG)
PIN NO. FUNCTION INPUT/OUTPUT

1 - -
26 Battery supply Input
27 Warning lamp Output
28 Ground Input
29 Driver airbag 1st stage, Low Output
30 Driver airbag 1st stage, High Output
31 Passenger airbag 1st stage, High Output
32 Passenger airbag 1st stage, Low Output
33 Driver belt pretensioner, Low Output
Page 6 of 90
34 Driver belt pretensioner, High Output
35 Output
High
36 Output
Low
37 Driver side airbag, Low Output
38 Driver side airbag, High Output
39 Passenger side airbag, High Output
40 Passenger side airbag, Low Output
Driver side airbag 2nd stage,
41 Output
Low
42 Driver side airbag 2nd, High Output
Passenger airbag 2nd statge,
43 Output
High
44 Passenger airbag 2nd stage, Low Output
45 - -
46 - -
47 - -
48 - -
49 - -
50 - -
51 ~ 53 - -
54 K-diagnostic line Input/output
55 - -
56 Crash output Output
57 - -
58 Enhanced crash output Output
59 - -
60 Driver seat track position sensor Input
61 Driver seat buckle switch0 Input
62 Passenger seat buckle switch Intput
Passenger seat track position
63 Intput
sensor
64 ~ 67 - -
Passenger side impact sensor,
68 Intput/output
Low
Passenger side impact sensor,
69 Input/output
High
Page 7 of 90
70 Driver side impact sensor, High Input/output
71 Driver side impact sensor, Low Input/output
Passenger front impact sensor,
72 Input/output
Low
Passenger front impact sensor,
73 Input/output
High
74 Driver front impact sensor, High Input/output
75 Driver front impact sensor, Low Input/output
Restraint > Supplemental Restraint System Control Module (SRnodeM) > Description and Operation
SRSCM
SRSCM (Supplement Restraint System Control Module)
1. DC/DC convertor : The DC/DC converter in the power supply includes a step-up and a step-down converter,
which provides the firing voltage for four firing circuits and the internal operating voltage. If the internal operating
voltage falls below a defined threshold, a reset is executed.
2. Arming sensor/safing sensor : The arming/safing sensor built in to the airbag firing circuit has the function of arming
the airbag circuit under all required deployment conditions and maintaining the airbag firing circuits unarmed under
normal driving conditions. The safing sensor is a dual-contact electromechanical switch that closes if it
experiences a deceleration exceeding a specified threshold.
3. Back-up power : The SRSCM reserves an energy reserve to provide deployment energy for a short period when
the vehicle voltage is low or if lost in a vehicle frontal crash.
4. Malfunction detection : The SRSCM continuously monitors SRS operating status while the ignition key is turned
on and detects possible malfunctions in the system. The malfunction can be displayed in the form of a diagnostic
trouble codes using the Hi-Scan Pro.
5. MIL (Malfunction Indication Lamp) notification : If any fault is detected, the SRSCM sends a signal to the
indicator lamp on the instrument cluster to warn the vehicle driver.
The MIL indicator is the key item in notifying the driver of SRS faults. It verifies lamp and SRSCM operation by
flashing 6 times when the ignition switch is first turned on.
6. Malfunction recording : Once a fault occurs in the system, the SRSCM records the fault in memory in the form of
a DTC, which can only be erased by the Hi-Scan Pro.
7. Data link connector : SRSCM memory stored is linked through this connector located underneath the driver side
crash pad to an external output device such as the Hi-Scan Pro.
8. What if only BPT's deploy.
9. Crash output
The crash output is used to unlock the doors in case of a crash. The crash output is : 0-200 μA in OFF mode
and 200mA in ON mode. During the unlock command, the switch is closed for 200 mS.
SRS HARNESS
SRSCM INDEPENDENT LAMP ACTIVATION
Page 8 of 90
1. Loss of ignition voltage supply to the SRSCM : lamp turned on continuously.

2. Loss of internal operating voltage: lamp turned on continuously.
3. SRSCM not connected: lamp turned on through shorting bar in wiring harness connector.
MIL OPERATING METHOD
DIAGNOSIS WITH SCAN TOOL

CHECK PROCEDURES
1. Connect the Hi-Scan Pro DLC to the vehicle's data link connector located underneath the dash panel.
2. Turn the ignition key to the "ON" position and turn the Hi-Scan Pro ON.
3. Perform the SRS diagnosis according to the vehicle model configuration.
4. If a fault code is assured, then replace the component. Never attempt to repair the component.
5. If the Hi-Scan Pro finds that a component of the system is faulty, there is a possibility that the fault is not in the
component, but in SRS wiring or connector.
SEAT TRACK POSITION SENSOR REPLACEMENT

REMOVAL
1. Disconnect the battery negative cable and wait at least three minutes before beginning work.
2. Remove the seat assembly.
Page 9 of 90
3. Disconnect the seat track position sensor 2P connector (A).
4. Remove the seat track position sensor (A).
INSTALLATION
Be sure to install the harness wires so that they are not pinched or interfering other parts.
1. Install the new seat track position sensor.
2. Connect the seat track position sensor 2P connector.
3. Install the seat assembly.
4. Reconnect the battery negative cable.
5. After installing the seat track position sensor, confirm proper system operation: Turn the ignition switch ON: the
SRS indicator light should blink for about six seconds and then go off.
6. Relining and side the front seat forward fully, make sure the harness wires are not wires not pinched or interfering
with other parts.
Restraint > Supplemental Restraint System Control Module (SRnodeM) > Components and
Components Location
SYSTEM COMPONENT AND LAYOUT
Page 10 of 90
Restraint > Supplemental Restraint System Control Module (SRnodeM) > Troubleshooting
DIAGNOSTIC TROUBLESHOOTING FLOW
Page 11 of 90
AIRBAG SQUIB RESISTANCE LIMITS

DAB
R ≤ 1.06Ω Resistance too low Fault definitely detected
1.8Ω ≤ 3.4Ω Resistance within tolerance Definitely no fault detected
R ≥ 6.7Ω Resistance too high Fault definitely detected
1.06Ω < R <1.6Ω Fault may or may not be
Tolerance band
2.8Ω < R < 6.7Ω detected
PAB, SAB, BPT

1.6Ω ≤ 2.8Ω Resistance within tolerance Definitely no fault detected
Tolerance band
SRE-SMART : DUAL STAGE AIRBAG

Page 12 of 90
DAB, DAB (2ND STAGE)
1.6Ω ≤ R ≤ 4.1Ω Resistance within tolerance Definitely no fault detected
Tolerance band
PAB, SAB, PAB (2ND STAGE)

Tolerance band
BPT
Tolerance band
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE

OPTIONS : DAB + PAB + SAB + BPT (SRE-LC)
DTC No. Fault description
B1111 Battery voltage too high
B1112 Battery voltage too low
B1346 Driver airbag (DAB), Resistance too high
B1347 Driver airbag (DAB), Resistance too low
B1348 Driver airbag (DAB), Short to ground
B1349 Driver airbag (DAB), Short to Battery
B1352 Passenger airbag (PAB), Resistance too high
B1353 Passenger airbag (PAB), Resistance too low
B1354 Passenger airbag (PAB), Short to ground
B1355 Passenger airbag (PAB), Short to Battery
Driver seat belt pretensioner (DBPT), Resistance too
B1361
high
Driver seat belt pretensioner (DBPT), Resistance too
B1362
low
B1363 Driver seat belt pretensioner (DBPT), Short to ground
B1364 Driver seat belt pretensioner (DBPT), Short Battery
Page 13 of 90
Passenger seat belt pretensioner (PBPT), Resistance
B1367
too high
Passenger seat belt pretensioner (PBPT), Resistance
B1368
too low
Passenger seat belt pretensioner (PBPT), Short to
B1369
ground
Passenger seat belt pretensioner (PBPT), Short to
B1370
Battery
B1378 Driver side airbag (DSAB), Resistance too High
B1379 Driver side airbag (DSAB), Resistance too Low
B1380 Driver side airbag (DSAB), Short to ground
B1381 Driver side airbag (DSAB), Short to Battery
B1382 Passenger side airbag (PSAB), Resistance too high
B1383 Passenger side airbag (PSAB), Resistance too low
B1384 Passenger side airbag (PSAB), Short to ground
B1385 Passenger side airbag (PSAB), Short to Battery
B1400 Satellite driver side sensor defect
B1401 Satellite driver side short to ground
B1402 Satellite driver side short to battery
B1403 Satellite passenger side sensor defect
B1404 Satellite passenger side short to ground
B1405 Satellite passenger side short to battery
B1620 Internal failure
B1650 Crash recorded (Frontal repace SRE-HMC)
B1661 Parameter configuration missing/incorrect
B2500 Warning lamp failure
OPTIONS : DAB+PAB+SAB+BPT (DUAL STAGE AIRBAG)

DTC No. Fault description
B1103 Communication voltage too low
B1326 Driver side front impact sensor short to ground
B1327 Driver side front impact sensor short to battery
B1328 Driver side front impact sesnor defect
B1329 Driver side front impact sesnor communication error
B1330 Driver side front impact sesnor wrong ID
B1331 Passenger side front impact sesnor short to ground
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B1332 Passenger side front impact sesnor short to battery
B1333 Passenger side front impact sesnor defect
B1334 Passenger side front impact sesnor communication error
B1335 Passenger side front impact sesnor wrong ID
B1346 1st stage driver airbag (DAB), Resistance too high
B1347 1st stage driver airbag (DAB), Resistance too low
B1348 1st stage driver airbag (DAB), Short to ground
B1349 1st stage driver airbag (DAB), Short to Battery
B1352 1st stage passenger airbag (PAB), Resistance too high
B1353 1st stage passenger airbag (PAB), Resistance too low
B1354 1st stage passenger airbag (PAB), Short to ground
B1355 1st stage passenger airbag (PAB), Short to Battery
B1361 Driver seat belt pretensioner (DBPT), Resistance too high
B1362 Driver seat belt pretensioner (DBPT), Resistance too low
B1363 Driver seat belt pretensioner (DBPT), Short to ground
B1364 Driver seat belt pretensioner (DBPT), Short Battery
B1367 Passenger seat belt pretensioner (PBPT), Resistance too high
B1368 Passenger seat belt pretensioner (PBPT), Resistance too low
B1369 Passenger seat belt pretensioner (PBPT), Short to ground
B1370 Passenger seat belt pretensioner (PBPT), Short to Battery
B1378 Driver side airbag (DSAB), Resistance too High
B1379 Driver side airbag (DSAB), Resistance too Low
B1380 Driver side airbag (DSAB), Short to ground
B1381 Driver side airbag (DSAB), Short to Battery
B1382 Passenger side airbag (PSAB), Resistance too high
B1383 Passenger side airbag (PSAB), Resistance too low
B1384 Passenger side airbag (PSAB), Short to ground
B1385 Passenger side airbag (PSAB), Short to Battery
B1387 Driver seat-track position sensor short to ground
B1388 Driver seat-track position sensor short to battery
B1389 Driver seat-track position sensor defect
B1390 Passenger seat-track position sensor short to ground
B1391 Passenger seat-track position sensor short to battery
B1392 Passenger seat-track position sensor defect
B1395 Firing loop interconnection fault
B1400 Side impact sensor driver side defect
Page 15 of 90
B1401 Side impact sensor driver side short to ground
B1402 Side impact sensor driver side short to battery
B1403 Side impact sensor passenger side sensor defect
B1404 Side impact sensor passenger side short to ground
B1405 Side impact sensor passenger side short to battery
B1409 Side impact sensor driver side communication error
B1410 Side impact sensor passenger side communication error
B1414 Side impact sensor driver side wrong ID
B1415 Side impact sensor passenger side wrong ID
B1481 2nd stage driver airbag, Resistance too high
B1482 2nd stage driver airbag, Resistance too low
B1483 2nd stage driver airbag, Short to ground
B1484 2nd stage driver airbag, Short to battery
B1485 2nd stage passenger airbag, Resistance too high
B1486 2nd stage passenger airbag, Resistance too low
B1487 2nd stage passenger airbag, Short to ground
B1488 2nd stage passenger airbag, Short to battery
B1511 Driver seat buckle switch short to battery
B1512 Driver seat buckle switch short to ground
B1513 Passenger seat buckle switch short to battery
B1514 Passenger seat buckle switch short to ground
B1515 Driver seat buckle switch defect
B1516 Passenger seat buckle switch defect
B1620 Internal failure
B1650 Crash recorded (Frontal-Replace SRE-SMART)
Crash recorded driver side airbag (Side Airbag-Replace SRE-
B1651
SMART)
Crash recorded passenger side airbag (Side Airbag-Replace
B1652
SRE-SMART)
B1657 Crash recorded-belt pretensioner only
2nd stage crash recorded (Frontal Airbag-Replace SRE-
B1670
SMART)
B2500 Warning lamp failure
Page 16 of 90
• The DAB is located in the steering wheel.

• The PAB is located in the crash pad.
• The DSAB is located in the out side of driver's seat.
• The PSAB is located in the out side of passenger's seat.
Restraint > Supplemental Restraint System Control Module (SRnodeM) > Repair procedures
REMOVAL
1. Disconnect the negative battery cable and keep secure from battery.
Wait at least 30 seconds after disconnecting the battery cable before doing any further
work.
2. Remove the center console mounting bolts (10mm).
3. Remove the center console.

4. Disconnect the SRSCM connector.
Page 17 of 90
5. Remove the SRSCM (10mm).
• Do not damage the SRSCM terminals or connectors.

• Do not disassemble the SRSCM; It has no serviceable parts.
• Store the SRSCM in a clean, dry area.
• Do not use any SRSCM which has been subjected to water or shows sign of being dropped or
improperly handled, such as dents, cracks or deformation.
6. After installing the SRSCM, confirm proper system operation: Turn the ignition switch ON ; the SRS indicatior
light should come on for about six seconds and then go off.
SIDE IMPACT SENSOR REPLACEMENT

REMOVAL
• Removal of the airbag must be performed according to the precautions/procedures decribed before.
• Before disconnecting the side impact sensor 2P connector(s), disconnect the side airbag 2P connector(s).
• Do not turn the ignition switch On and do not connect the battery cable while exchanging the side impact
sensor.
1. Disconnect the negative battery cable, and wait at least three minutes before work.
2. Remove the seat assembly.
3. Remove the front door sill trim.
4. Remove the center pillar trim.
5. Remove the lower anchor bolt.
6. Remove the belt pretensioner.
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7. Remove the bolt then remove the side impact sensor.
Torque
8 ~ 10Nm (80 ~ 100kg.cm, 6 ~ 7.4lb.ft)
8. Disconnect the SRS harness 2P connector from the side impact sensor.
INSTALLATION
• Be sure to install the harness wires so that they are not pinched or interfering with other parts.
• Do not turn the ignition switch ON and do not connect the battery cable while exchanging the side impact
sensor.
1. Install the new side impact sensor with bolts then connect the SRS harness 2P connector to the side impact
sensor.
2. Reinstall belt pretensioner.
4. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON: the SRS
indicator light should blink for above six seconds and then go off.
FRONT IMPACT SENSOR REPLACEMENT
REMOVAL
• Removal of the airbag must be performed according to the precautions/ procedures described before.
• Before disconnecting the front impact sensor 2P connector, disconnect the front airbag 4P connector(s).
• Do not turn the ignition switch ON and do not connect the battery cable while exchanging the front impact
sensor.
1. Disconnect the negative battery cable and wait at least three minutes before beginning work.
2. Remove the bolt then remove the front impact sensor.
3. Disconnect the SRS harness 2P connector from the front impact sensor.
INSTALLATION
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• Be sure to install the harness wire so that they are not pinched or interfering with other parts.
• Do not turn the ignition switch ON and do not contact the battery cable while exchanging the front impact
sensor.
1. Install the new front impact sensor with bolt then connect the SRS harness 2P connector to the front impact
sensor.
3. After installing front impact sensor, confirm proper system operation: Turn the ignition switch ON: the SRS
indication light should blink for about six seconds and then go off.
Restraint > Airbag Module > Description and Operation

FIELD DEPLOYMENT PROCEDURES
When handling the deployed airbag be careful that not the dust enters your eyes and always wear gloves to avoid
direct contact with the dust.
AIRBAG MODULE DISPOSAL PROCEDURES
AIRBAG REMOTE DEPLOYMENT DEVICES
Tool, Number, Name Use
Deployment tool (0957A-34100A) Deployment inside the vehicle (if the vehicle will no
SRS DEPLOYMENT ADAPTER HARNESS longer be driven)
DAB, BPT : 0957A-38500
PAB, SAB : 0957A-38100
PAB : 0957A-2500 (Dual stage)
DISPOSAL PLAN
CASE DISPOSAL PLAN
Abnormal problems in airbag
Deploy and discard
module
DAB, PAB,
Car scrapping Deploy the airbag module with the SST
BPT, SAB
Crash (Deployed) Discard
UNDEPLOYED AIRBAG MODULE DISPOSAL
1. If the vehicle is to be scrapped, junked, or otherwise disposed of, deploy the airbag inside the vehicle.
2. Since there is a loud noise when the airbag is deployed, avoid residential areas whenever possible. If anyone is
nearby, give warning of the impending noise.
3. Since a large amount of smoke is produced when the airbag is deployed, select a well-ventilated site.
Moreover, never attempt the test near a fire or smoke sensor.
When scrapping a car or intentionally deploying the replaced airbag modules, deploy individual stage.
DEPLOYMENT INSIDE THE VEHICLE
when vehicle will no longer be driven
Page 20 of 90
1. Open all windows and doors of the vehicle. Move the vehicle to an isolated spot.
2. Disconnect the negative (-) and positive (+) battery cables from the battery terminals, and then remove the
battery from the vehicle.
Wait at least 30 seconds after disconnecting the battery cable before doing any further work.
3. Remove the center crash pad side cover.
4. Remove Airbag SRSCM connector.
5. Connect deployment tool to the connector of each module.
6. At location as far away from the vehicle as possible, press the push button (removed from the vehicle) to deploy
the airbag.
1. Before deploying the airbag in this manner, first check to be sure that there is no one in or near the
vehicle. Wear safety glasses.
2. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow
it to cool before attempting to handle it. Although not poisonous, do not inhale gas from airbag
deployment. See Deployed Airbag Module Disposal Procedures for post-deployment handling
instructions.
3. If the airbag fails to deploy when the procedures above are followed, do not go near the module.
Contact your local distributor.
DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURES

1. The inflator will be quite hot immediately following deployment, so wait at least 30 minutes to allow it to cool
before attempting to handle it.
2. Do not put water or oil on the airbag after deployment.
3. There may be adhered to the deployed airbag module, material that could irritate the eyes and/or skin, so wear
gloves and safety glasses when handling a deployed airbag module. If despite these precautions, the material does
get into your eyes or on your skin, immediately rinse the affected area with a large amount of clean water. If any
irritation develops, seek medical attention.
4. Tightly seal the airbag module in a strong vinyl bag for disposal.
5. Be sure to always wash your hands after completing this operation.

Page 21 of 90
Restraint > Airbag Module > Components and Components Location

COMPONENTS
Restraint > Airbag Module > Repair procedures

REMOVAL
Page 22 of 90
1. Disconnect the battery negative (-) terminal cable.
Wait at least 30 seconds.
2. Disconnect the side airbag harness 2p connector.

3. Remove the seat assembly and seat-back cover.
4. Remove the two mounting nuts and the side airbag.
1. Never attempt to disassemble or repair the airbag module.

2. Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust are detected.
3. The airbag module should be stored on a flat surface and placed so that the pad surface is facing
upward. Do not place anything on top of it.
4. Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the
specified tester. If the circuit resistance is measured with a tester, accidental airbag deployment will
result in serious personal injury.
REMOVAL
Page 23 of 90
1. Disconnect the negative battery cable and keep secure from battery.
Wait at least 30 seconds after disconnecting the battery cable before doing any further
work.
2. Remove the side protect cover of steering wheel and airbag module mounting bolts using a hexagonal wrench.
3. Disconnect the drive airbag module connector.

SRE-LC
Dual stage airbag
The removed airbag module should be stored in a clean, dry place with the pad cover face
up.
Page 24 of 90
4. Remove the steering wheel using SST (09561-11002).
Do not hammer on the steering wheel. Doing so may damage the collapsible column
mechanism.
5. Remove the steering column upper shroud and lower shroud.
6. When disconnecting the connector of the clock spring from the airbag module, pull the airbag's lock toward the
outer side to spread it open.
When disconnecting the airbag module-clock spring connector, take care not to apply excessive force to
it.
INSPECTION
Page 25 of 90
AIRBAG MODULE
Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified
tester. If the circuit resistance is measured with a tester, accidental airbag deployment will result in serious personal
injury.
1. Check pad cover for dents, cracks or deformities.
2. Check the airbag module for denting, cracking or deformation.
3. Check hooks and connectors for damage, terminals for deformities, and harness for binds.
4. Check airbag inflator case for dents, cracks or deformities.
5. Install the airbag module to the steering wheel to check for fit or alignment with the wheel.
CLOCK SPRING
1. If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a new
one.
2. Check connectors and protective tube for damage, and terminals for deformities.
Restraint > Airbag Module > Passenger Airbag (PAB) Module > Repair procedures
REMOVAL
Page 26 of 90
1. Never attempt to disassemble or repair the airbag module.

2. Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust are detected.
3. The airbag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do
not place anything on top of it.
4. Do not expose the airbag module to temperature over 93°C (200°F)
5. An undeployed airbag module should only be disposed in accordance with the procedures.
6. Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified
tester. If the circuit resistance is measured with a tester, accidental airbag deployment will result in serious
personal injury.
7. Whenever the PAB is deployed it should be replaced with a new one assembled with an extension wire. The
squib is melt down if the PAB is deployed making the extension wire useless.
1. Disconnect the battery negative (-) terminal cable.
2. Remove the glove box.

Page 27 of 90
3. Disconnect the PAB module connector.
SRE-LC
Dual stage airbag
4. Remove the crash pad assembly and then undo the PAB module. (Refer to the BD section)
Restraint > Seat Belt Pretensioner > Seat Belt Retractor Pretensioner (BPT) > Repair procedures
REMOVAL
Page 28 of 90
1. Disconnect the battery negative (-) terminal.
2. Remove the door scuff trim.
3. Remove the lower anchor plate cover and lower anchor plate.
4. Remove the center pillar lower trim.

Page 29 of 90
5. Remove the upper anchor plate cover and upper anchor plate.
6. Disconnect the belt pretensioner connector.
7. Remove the front seat belt.
1. Never attempt to disassemble or repair the BPT.

2. Do not drop the BPT or allow contact with water, grease, oil.
Replace it if a dent, crack, deformation or rust are detected.
3. Do not place anything on the BPT.
4. Do not expose the BPT to temperature over 93°C(200°F).
5. BPT functions one time only. Be sure to replace the BPT after it is
deployed.
6. Be sure to wear gloves and safety goggles when handling the deployed
BPT.
Page 30 of 90
Restraint > Troubleshooting > B1101

CIRCUIT INSPECTION (DUAL STAGE AIRBAG)
DTC
B1103 Communication voltage too
low
CIRCUIT DESCRIPTION
INSPECTION PROCEDURE
1. Preparation
A. Disconnect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
B. Remove the DAB module.
C. Disconnect the connectors of the PAB, left and right side airbags, belt pretensioners and satellite sensors.
D. Disconnect the SRSCM connector.
Place the DAB with the front surface facing upward.
2. Check source voltage.

A. Connect the negative (-) terminal cable to the battery.
B. Turn the ignition switch ON.
LIMIT : 10 ~ 16.5V
Page 31 of 90
3. Does the SRS warning light turn off ?
A. Turn the ignition switch to LOCK.
B. Connect the DAB module.
C. Connect the PAB connector, left and right side airbag, belt pretensioner and satellite connectors.
D. Connect the SRSCM connector.
E. Turn the ignition switch ON.
(1)

CIRCUIT INSPECTION (SRE-LC)
DTC
CIRCUIT DESCRIPTION
1. Preparation
[email protected]
Page 32 of 90
2. Check source voltage.
B. Turn the ignition switch ON.
LIMIT : 9 ~ 16V
3. Does the SRS warning light turn off ?

B. Connect the DAB module.
C. Connect the PAB connector, left and right side airbag, belt pretensioner and satellite connectors.
D. Connect the SRSCM connector.
E. Turn the ignition switch ON.

B1326 Driver side front impact sensor short to ground
B1331 Passenger side front impact sensor short to
ground
B1348 1st stage DAB Short to ground
B1354 1st stage PAB Short to ground
B1363 DBPT Short to ground
B1369 PBPT Short to ground
DTC
B1380 DSAB Short to ground
B1384 PSAB Short to ground
B1401 Side impact sensor driver side short to ground
B1404 Side impact sensor passenger side short to
ground
B1483 2nd stage DAB short to ground
B1487 2nd stage PAB short to ground
Page 33 of 90
CIRCUIT DESCRIPTION
DTC Detecting Condition Trouble Area
• Short circuit in squib wire harness (to ground) • 1st stage DAB squib • 2nd stage DAB
• Squib malfunction • 1st stage PAB squib squib
• Clock spring malfunction • DSAB squib • 2nd stage PAB
• SRSCM malfunction • PSAB squib squib
• BPT squib • Front impact sensor
• Side impact sensor
• Clock spring
• SRSCM
• Wire harness
WIRING DIAGRAM
1. Preparation
[email protected]
Page 34 of 90
2. Check the DAB squib circuit.
[CHECK]
For the connector (on the clock spring side) between the clock spring and the DAB, measure the resistance
between the DAB high and body ground.
Resistance: ∞
3. Check the PAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the PAB, measure the resistance between the
PAB high and body ground.
Resistance: ∞
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4. Check the PSAB and DSAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the SAB, measure the resistance between the
SAB high and body ground.
Resistance: ∞
5. Check the BPT squib circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the BPT, measure the resistance between the
BPT high and body ground.
Resistance: ∞
[email protected]
Page 36 of 90
6. Check the side impact sensor circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the side impact sensor, measure the
resistance between the side impact sensor high and body ground.
Resistance: ∞
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the front impact sensor, measure the
resistance between the front impact sensor high and body ground.
Resistance: ∞
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8. Check the SRSCM.
A. Connect the connector to the SRSCM.
B. Using a service wire, connect the DAB high and the DAB low to the clock spring side connector between the
clock spring and the DAB.
C. Using a service wire, connect the PAB high and low on the SRSCM side of the connector between the
SRSCM and the PAB.
D. Connect the SAB, the BPT, the FIS and the SIS by the same method.
E. Connect the negative (-) terminal cable to the battery, and wait least 30 seconds.
A. Turn the ignition switch to ON, and wait at least 30 seconds.

B. Clear the malfunction code stored in the memory with the Hi-Scan Pro.
C. Turn the ignition switch to LOCK, and wait for 30 seconds.
D. Turn the ignition switch to ON, and wait for 30 seconds.
E. Using Hi-Sacn Pro, check the DTC.
There is no DTC.
[HINT]
Codes other than these ones may be output at this time, but they are not relevant to this check.
9. Check the DAB squib.

B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the the DAB connector.
D. Connect the negative (-) terminal cable to the battery, and wait for 30 seconds.
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
[email protected]
Page 38 of 90
E. Using the Hi-scan, check the DTC.
There is no DTC.
10. Check the PAB squib.

C. Connect the the PAB connector.
D. Connect the negative (-) terminal cable from the battery, and wait for 30 seconds.
B. Clear the malfunction code stored in the memory with Hi-Scan Pro.
E. Using the Hi-Sacn Pro, check the DTC.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.
Page 39 of 90
11. Check the SAB squib.
C. Connect the the SAB connector.
D. Turn the ignition switch ON, and wait for 30 seconds.
There is no DTC.
[HINT]
12. Check the BPT squib.

A. Turn the ignition swich to LOCK.
C. Connect the BPT connector.
A. Turn the ignition switch to ON, and wait for 30 seconds.

E. Using the Hi-Scan Pro, check the DTC.
There is no DTC.
[HINT]
[email protected]
Page 40 of 90
13. Check the side impact sensors.

A. Turn ignition switch to LOCK.
B. Disconnect negative (-) terminal cable from the battery, and wait at least 30 seconds.
C. Connect the side impact sensor connector.
D. Connect the negative (-) terminal cable from the battery, and wait at least 30 seconds.

B. Clear the malfunction code stored in memory with the Hi-Scan Pro.
C. Turn the ignition switch to LOCK, and wait at least 30 seconds.
D. Turn the ignition switch to ON, and wait at least 30 seconds.
E. Using the Hi-Scan Pro, check for DTCs.
There is no DTC.
[HINT]
Page 41 of 90
14. Check the front impact sensors.
B. Disconnect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
C. Connect the front impact sensor connector.
D. Commect the negative (-) terminal cable from the battery, and wait at least 30 seconds.

There is noDTC.
[HINT]
15. Check the clock spring circuit.
[CHECK]
Measure the resistance between the DAB high on the clock spring side of the connector between the clock
spring and the DAB and body ground.
Resistance: ∞
Restraint > Troubleshooting > B1327 [email protected]

Page 42 of 90
B1327 Driver side front impact sensor short to battery
B1332 Passenger side front impact sensor short to
battery
B1349 1st stage DAB Short to battery
B1355 1st stage PAB Short to battery
B1364 BPT (Driver) Short to battery
B1370 BPT (Passenger) Short to battery
DTC
B1381 SAB (Driver) short to battery
B1385 SAB (Passenger) short to battery
B1402 Side impact sensor driver side short to battery
B1405 Side impact sensor passenger side short to
battery
B1484 2nd stage DAB shrot to battery
B1488 2nd stage PAB short to battery
CIRCUIT DESCRIPTION
• Short circuit in squib wire harness (to B+) • 1st stage DAB • 2nd stage DAB
• Squib malfunction squib squib
• Spiral cable malfunction • 1st stage PAB squib • 2nd stage PAB
• SRSCM malfunction • DSAB or PSAB squib
squib • Front impact sensor
• BPT squib
• Side impact sensor
• Wire harness
WIRING DIAGRAM
Page 43 of 90
1. Preparation
[CHECK]
For the connector (on the clock spring side) between the clock spring and the DAB, measure the voltage
Voltage : 0 V
[email protected]
Page 44 of 90
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the PAB, measure the voltage between the
Voltage : 0 V
4. Check the SAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the SAB, measure the voltage between the
Voltage : 0 V
Page 45 of 90
[CHECK]
For the connector between the SRSCM and the BPT, measure the voltage between the BPT high and body
ground.
Voltage : 0 V
[CHECK]
For the connector between the SRSCM and the side impact sensor, measure the voltage between the side
impact sensor high and body ground.
Voltage : 0 V
[email protected]
Page 46 of 90
7. Check the front impact sensor circuit.
[CHECK]
For the connector between the SRSCM and the front impact sensor, measure the voltage between the front
impact sensor high and body ground.
Voltage : 0 V
8. Check the SRSCM.

B. Using a service wire, connect the DAB high and low on the clock spring side of the connector between the
SRSCM and the PAB.
D. Using a service wire, connect the SAB, BPT, FIS and by the same method.
E. Connect negative (-) battery cable to the battery, and wait at least 30 seconds.
B. Clear the malfunction code stored in memory with Hi-Scan Pro.
E. Using Hi-Scan Pro, check the DTC.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this check.
Page 47 of 90

C. Connect the DAB connector.
There is no DTC.
[HINT]
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Page 48 of 90
There is no DTC.
[HINT]

C. Connect the SAB connector.
There is no DTC.
[HINT]
Codes other than these ones may be output at this time, but they are not relevant to this checking procedure.
Page 49 of 90

C. Connect the the BPT connector.

E. Using the Hi-Scan Pro check the DTC.
There is no DTC.
[HINT]
[email protected]
Page 50 of 90
13. Check the side impact sensors.

B. Clear the malfunction code stored in memory with Hi-scan Pro.
There is no DTC.
[HINT]
14. Check the front impact sensors.

C. Connect the front impact sensor connector

B. Clear the malfunction code stored in memory with Hi-scan.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure
Page 51 of 90
15. Check the clock spring.

B. Disconnect the connector between the SRSCM and the clock spring.
1. [CHECK]
Turn the ignition switch to ON, and measure voltage between the DAB high and body ground.
Voltage : 0 V

B1328 Front impact sensor driver side defect
B1329 Front impact sensor driver communication error
B1330 Front impact sensor driver side wrong ID
DTC B1333 Front impact sensor passenger side defect
B1334 Front impact sensor passenger communication
error
B1335 Front impact sensor passenger side wrong ID
CIRCUIT DESCRIPTION
WIRING DIAGRAM
[email protected]
Page 52 of 90
1. Preparation
D. Disconnect the connector of theSRSCM.
2. Check the front impact sensor circuits (Communication error).
[PREPARATION]
Check sensor continuity between sensor SRSCM connector and both front impact sensor connector's high (+)
and low (-) sides.
OK : Continuity
Page 53 of 90
3. Check the front impact sensor (Defect).

C. Connect the front impact sensor connector.
B. Clear the malfunction code stored in the memory of the Hi-Scan Pro.
There is no DTC.
[HINT]

B1346 DAB resistance too high (R ≥ 6.0Ω)
B1347 DAB resistance too low (R ≤ 0.9Ω)
B1481 2nd stage DAB resistance too high (R ≥
DTC
6.0Ω)
B1482 2nd stage DAB resistance too low (R ≤
0.9Ω)
CIRCUIT DESCRIPTION
[email protected]
Page 54 of 90
• Too high or low resistane between DAB high (+) • 1st stage DAB squib
wiring harness and DAB low (-) wiring harness of • Clock spring
squib. • SRSCM
• DAB malfunction • Wire harness
• Clock spring malfunction • 2nd stage DAB squib
• SRSCM malfunction
WIRING DIAGRAM
1. Preparation
Page 55 of 90
2. Check the DAB resistance.

[PREPARATION]
Release the airbag activation prevention mechanism on SRSCM side of airbag squib side. Connect the dummy
(0957A-38200) and dummy adapter (0957A-1C000) to the clock spring side connector.
Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the
specified tester.
Before checking the resistance, you have to insert the shorting bar insert plastic that is attached to the
diagnosis checker into the SRSCM connector.
[CHECK]
Measure the resistance between the DAB high (+) and low (-).
1.6Ω ≤ R ≤ 4.1Ω
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Page 56 of 90
There is no DTC.
[HINT]

[PREPARAION]
Disconnect the connector between the SRSCM clock spring, to the clock spring side connector.
[CHECK]
Measure the resistance between the DAB high (+) and low (-).
1.6Ω ≤ R ≤ 4.1Ω
Page 57 of 90

B1348 DAB Short to ground
B1354 PAB Short to ground
B1363 DBPT Short to ground
B1369 PBPT Short to ground
B1380 DSAB Short to ground
DTC
B1384 PSAB Short to ground
B1401 Satellite sensor left side short to
ground
B1404 Satellite sensor right side short to
ground
CIRCUIT DESCRIPTION
• Short circuit in squib wire • DAB squib
harness (to ground) • PAB squib
• Squib malfunction • DSAB squib
• Clock spring malfunction • PSAB squib
• SRSCM malfunction • BPT squib
• Satellite sensor
• Clock spring
• SRSCM
• Wire harness
WIRING DIAGRAM
[email protected]
Page 58 of 90
1. Preparation

Page 59 of 90
[CHECK]
For the connector (on the clock spring side) between the clock spring and the DAB, measure the resistance
Resistance: ∞
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the PAB, measure the resistance between the
Resistance: ∞
[email protected]
Page 60 of 90
4. Check the PSAB and DSAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the SAB, measure the resistance between the
Resistance: ∞
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the BPT, measure the resistance between the
BPT high and body ground.
Resistance: ∞
Page 61 of 90
6. Check the Satellite sensor circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the Satellite sensor, measure the resistance
between the Satellite high and body ground.
Resistance: ∞
7. Check the SRSCM.

B. Using a service wire, connect the DAB high and the DAB low to the clock spring side connector between the
SRSCM and the PAB.
D. Connect the SAB and the BPT by the same method.
E. Connect the negative (-) terminal cable to the battery, and wait least 30 seconds.

E. Using Hi-Sacn Pro, check the DTC.
There is no DTC.
[HINT]
Codes other than these ones may be output at this time, but they are not relevantto this check.
[email protected]
Page 62 of 90

C. Connect the the DAB connector.
E. Using the Hi-scan, check the DTC.
There is no DTC.

Page 63 of 90
There is no DTC.
[HINT]

C. Connect the the SAB connector.
There is no DTC.
[HINT]
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Page 64 of 90

E. Using the Hi-Scan Pro, check the DTC.
There is no DTC.
[HINT]
12. Check the Satellite sensors.

B. Disconnect negative (-) terminal cable from the battery, and wait at least 30 seconds.
C. Connect the Satellite sensor connector.
There is no DTC.
[HINT]
Page 65 of 90
13. Check the clock spring circuit.
[CHECK]
Measure the resistance between the DAB high on the clock spring side of the connector between the clock
spring and the DAB and body ground.
Resistance: ∞

B1349 DAB Short to battery
B1355 PAB Short to battery
B1364 BPT (Driver) Short to battery
B1370 BPT (Passenger) Short to
battery
DTC B1381 SAB (Driver) short to battery
B1385 SAB (Passenger) short to
battery
B1402 Satellite left side short to battery
B1405 Satellite right side short to
battery
CIRCUIT DESCRIPTION
• Short circuit in squib wire • DAB squib
harness (to B+) • PAB squib
• Squib malfunction • DSAB or PSAB squib
• Spiral cable malfunction • BPT squib
• SRSCM malfunction • Satellite sensor
• Wire harness
WIRING DIAGRAM
[email protected]
Page 66 of 90
1. Preparation

Page 67 of 90
[CHECK]
For the connector (on the clock spring side) between the clock spring and the DAB, measure the voltage
Voltage : 0 V
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the PAB, measure the voltage between the
Voltage : 0 V
[email protected]
Page 68 of 90
4. Check the SAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the SAB, measure the voltage between the
Voltage : 0 V
[CHECK]
For the connector between the SRSCM and the BPT, measure the voltage between the BPT high and body
ground.
Voltage : 0 V
Page 69 of 90
6. Check the Satellite sensor circuit.
[CHECK]
For the connector between the SRSCM and the Satellite sensor, measure the voltage between the Satellite
sensor high and body ground.
Voltage : 0 V
7. Check the SRSCM.

B. Using a service wire, connect the DAB high and low on the clock spring side of the connector between the
SRSCM and the PAB.
D. Using a service wire, connect the SAB high and low on the SRSCM side connector between the SRSCM
and the SAB.
E. Using a service wire, connect the BPT high and low on the SRSCM side connector between the SRSCM and
the BPT.
F. Using a service wire, connect the satellite high and low on the SRSCM side connector between the SRSCM
and the satellite sensor.
G. Connect negative (-) battery cable to the battery, and wait at least 30 seconds.
B. Clear the malfunction code stored in memory with Hi-Scan Pro.
There is no DTC.
[HINT]
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Page 70 of 90

There is no DTC.
[HINT]
Page 71 of 90
DTC is not output.
[HINT]

There is no DTC.
[HINT]
Codes other than these ones may be output at this time, but they are not relevant to this checking procedure.
[email protected]
Page 72 of 90

C. Connect the the BPT connector.

E. Using the Hi-Scan Pro check the DTC.
There is no DTC.
[HINT]
Page 73 of 90
12. Check the Satellite sensors.
C. Connect the Satellite sensor connector.

B. Clear the malfunction code stored in memory with Hi-scan Pro.
There is no DTC.
[HINT]

B. Disconnect the connector between the SRSCM and the clock spring.
[CHECK]
Turn the ignition switch to ON, and measure voltage between the DAB high and body ground.
Voltage : 0 V
[email protected]
Page 74 of 90
B1352 1st stage PAB resistance too high (R ≥
4.2Ω)
B1353 1st stage PAB resistance too low (R ≤
1.0Ω)
DTC
B1485 2nd stage PAB resistance too high (R ≥
4.2Ω)
B1486 2nd stage PAB resistance too low (R ≤
1.0Ω)
CIRCUIT DESCRIPTION
• Too high or low resistane between PAB high (+) • 1st stage PAB squib
wiring harness and PAB low (-) wiring harness of • SRSCM
squib. • Wire harness
• PAB malfunction • 2nd stage PAB squib
WIRING DIAGRAM
Page 75 of 90
1. Preparation
2. Check the PAB resistance.

[PREPARATION]
Release the airbag activation prevention mechanism on the SRSCM side of the airbag squib side. Connect the
dummy (0957A-38200) and dummy adapter (0957A-25100) to PAB connector of the SRSCM connector side.
[CHECK]
Measure the resistance between the PAB high (+) and the PAB low (-).
1.8Ω ≤ R ≤ 2.8Ω
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Page 76 of 90
C. Connect the PAB connector.
There is no DTC.
[HINT]

B1361 DBPT Resistance too high (R ≥
4.7Ω)
B1362 DBPT Resistance too low (R ≤
0.9Ω)
DTC
B1367 PBPT Resistance too high (R ≥
4.7Ω)
B1368 PBPT Resistance too low (R ≤
0.9Ω)
CIRCUIT DESCRIPTION
• Too high or low resistane between BPT high (+) • BPT squib
wiring harness and BPT low (-) wiring harness of • SRSCM
• BPT malfunction
Page 77 of 90
WIRING DIAGRAM
1. Preparation
[email protected]
Page 78 of 90
2. Check the BPT resistance.
[PREPARATION]
dummy (0957A-38200) and dummy adapter (0957A-1C000) to the BPT connector of the SRSCM connector
side.
[CHECK]
Measure the resistance between the BPT high (+) and the BPT low (-).
1.8Ω ≤ R ≤ 3.1Ω

There is no DTC.
[HINT]
Page 79 of 90

B1378 DSAB Resistance too high (R ≥
4.2Ω)
B1379 DSAB Resistance too low (R ≤
1.0Ω)
DTC
B1382 PSAB Resistance too high (R ≥
4.2Ω)
B1383 PSAB Resistance too low (R ≤
1.0Ω)
CIRCUIT DESCRIPTION
• Too high or low resistane between SAB high (+) • SAB squib
wiring harness and SAB low (-) wiring harness of • SRSCM
• SAB malfunction
WIRING DIAGRAM
[email protected]
Page 80 of 90
1. Preparation

Page 81 of 90
2. Check the SAB resistance.
[PREPARATION]
dummy (0957A-38200) and dummy adapter (0957A-38300) to the SAB connector of the SRSCM connector
side.
[CHECK]
Measure the resistance between the SAB high (+) and the SAB low (-).
1.8Ω ≤ R ≤ 2.8Ω

There is no DTC.
[HINT]
[email protected]
Page 82 of 90

B1387 Driver seat track position sensor short to GND
B1388 Driver seat track position sensor short to Battery
B1389 Driver seat track position sensor defect
B1390 Passenger seat track position sensor short to
DTC
GND
B1391 Passenger seat track position sensor short to
Battery
B1392 Passenger seat track position sensor defect
CIRCUIT DESCRIPTION
1. Preparation
2. Check seat track position sensor circuit (Short to GND/Battery).
[CHECK]
Page 83 of 90
Measure the voltage and resistance of the seat track position sensor high and body ground between the SRSCM
connector and the seat track position sesnor connector.
Resistance : ∞
Voltage : 0 V
3. Check the seat track position sensor.
[CHECK]
Check the resistance.
SWITCH OPEN : R = 900Ω ± 10% (Backward : over 5 clicks)
SWITCH CLOSED : R = 300Ω ± 10% (Forward : within 5 clicks)
4. Check the seat track position sensor. (Defect)

C. Connect the seat track position sensor connector.
There is no DTC.
[HINT] [email protected]
Page 84 of 90

B1395 Firing loop interconnection fault
B1620 Internal fault
B1650 Crash recorded (Frontal airbag)
B1651 Crash recorded (Driver side airbag)
B1652 Crash recorded (Passenger side
DTC
airbag)
B1657 Crash recorded (Belt pretensioner
only)
B1670 2nd stage crash recorded (Frontal
airbag)
CIRCUIT DESCRIPTION
1. Condition of the firing circuit activation transistors.
2. Adequacy of deployment energy reserves.
3. Safing sensor integrity. (detection of faulty closure)
4. Plausibility of the accelerometer signal.
5. Operation of the SRSCM components.

B1400 Side impact sensor driver side defect
B1403 Side impact sensor passenger side defect
B1409 Side impact sensor driver communication error
DTC B1410 Side impact sensor passenger communication
error
B1414 Side impact sensor driver side wrong ID
B1415 Side impact sensor passenger side wrong ID
CIRCUIT DESCRIPTION
WIRING DIAGRAM
Page 85 of 90
1. Preparation
2. Check side impact sensor circuits (Communication error).
[PREPARATION]
Check side impact sensor continuity between sensor SRSCM connector and both side impact connector's high
(+) and low (-) sides.
OK : Continuity
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Page 86 of 90
3. Check the side impact sensor (Defect).

There is no DTC.
[HINT]

B1511 Driver seat buckle switch open/short to Battery
B1512 Driver seat buckle switch short to GND
B1513 Passenger seat buckle swithch open/short to
DTC Battery
B1514 Passenger seat buckle swithch short to GND
B1515 Driver seat buckle switch defect
B1516 Passenger seat buckle switch defect
CIRCUIT DESCRIPTION
Page 87 of 90
1. Preparation
2. Check buckle switch sensor circuit (Short to GND/Battery).
[CHECK]
Measure the voltage and resistance of the seat track position sensor high and body ground between the SRSCM
connector and the seat track position sesnor connector.
Resistance : ∞
Voltage : 0 V
[email protected]
Page 88 of 90
3. Check the seat belt switch.
[CHECK]
Check the resistance with the switch on and off.
Buckled : 4.5mA < I < 5.5mA (R = 1000Ω ± 10%)
Unbuckled : 11.3mA < I < 13.8mA (R = 400Ω ± 10%)
4. Check the seat buckle switch (Defect).

C. Connect the seat buckle switch connector.
There is no DTC.
[HINT]
Page 89 of 90
B1620 Internal fault
B1650 Crash recorded (Frontal-Replace
DTC
SRSCM)
B1661 Parameter configuration missing/incorrect
CIRCUIT DESCRIPTION
1. Condition of the firing circuit activation transistors.
2. Adequacy of deployment energy reserves.
3. Safing sensor integrity. (detection of faulty closure)
4. Plausibility of the accelerometer signal.
5. Operation of the SRSCM components.

DTC B2500 Warning lamp failure
1. Check the fuse.
A. Remove fuse airbag fuse and airbag warning lamp fuse from the junction block.
B. Inspect the state of the fuses.
C. Replace if necessary.
2. Check the SRS warning lamp circuit.
B. Turn the ignition switch to ON.
A. Measure voltage at the harness side connector of the SRSCM.
Voltage: 9-16 V
B. Check the SRS SRI (Service Reminder Indicator).

OK: SRS SRI ON

DTC B2500 Warning lamp failure
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Page 90 of 90
1. Check the fuse.
A. Remove fuse airbag fuse and airbag warning lamp fuse from the junction block.
B. Inspect the state of the fuses.
C. Replace if necessary.
2. Check the SRS warning lamp circuit.
B. Turn the ignition switch to ON.
A. Measure voltage at the harness side connector of the SRSCM.
Voltage : 10-16.5 V
B. Check the SRS SRI (Service Reminder Indicator).

OK : SRS SRI ON
Page 1 of 57
ACCENT(LC) > 2005 > G 1.5 SOHC > Steering System
Steering System > General Information > General Information

GENERAL
CHECKING STEERING WHEEL FREE PLAY
1. Start the engine with the steering wheel in the straight ahead position.
2. Measure the play at the circumference of the steering wheel.
Standard value
Steering wheel free play : 0~30 mm (0~1.1 in.)
3. If the play exceeds the standard value, inspect the connection between the steering shaft and steering linkage.
CHECKING STEERING ANGLE
1. Place the front wheel on a turning radius gauge and measure the steering angle.
Standard value
Wheel angle (Unladen state)
Inner wheel : 37°37´ ± 1°30´
Outer wheel : 31°51´
2. If the measured value is not within the standard value, adjust the toe and inspect again.
CHECKING THE TIE ROD END BALL JOINT STARTING TORQUE
1. Disconnect the tie rod and knuckle by using the special tool.
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Page 2 of 57
2. Move the ball joint stud in a circular motion several times to check for looseness.
3. Mount the nuts on the ball joint, and then measure the ball joint starting torque.
Standard value
0.5~2.5 Nm (5~25 kg·cm, 0.36~1.78 lb·ft)
4. If the starting torque exceeds the upper limit of the standard value, replace the tie rod end.
5. Even if the starting torque is below the lower limit of the standard value, check the play of the ball joint and
replace if necessary.
CHECKING STATIONARY STEERING EFFORT
1. Position the vehicle on a level surface and place the steering wheel in the straight ahead position.
2. Increase the engine speed to 1000 ± 100 rpm.
After checking, reset the engine speed to the standard value (idling
speed).
3. Measure the turning force with a spring scale by turning the steering wheel clockwise and counterclockwise one
and a half turns.
Standard value
Stationary steering effort : 34.3N (3.5 kg, 7.8 lbs)
4. Check that there is no sudden change of force while turning the steering wheel.
5. If the stationary steering effort is excessive, check and adjust the following points.
(1) Damage or cracks on the dust cover and tie rod end ball joint.
(2) Pinion preload of the steering gear box and starting torque of the tie rod end ball joint.
(3) Starting torque of the ball joint.
CHECKING STEERING WHEEL RETURN
1. The force required to turn the steering wheel and the wheel return should be the same for both left and right in
case of moderate or sharp turns.
Page 3 of 57
2. When the steering wheel is turned 90° and held for a couple of seconds while the vehicle is being driven at
35kph, the steering wheel should return at least 70° from the neutral position when it is released.
If the steering wheel is turned very quickly, steering may be momentarily difficult. This is not a malfunction
because the oil pump output will be somewhat decreased.
CHECKING POWER STEERING BELT TENSION
1. Press the V belt, applying a pressure of 98N (10kg, 22lb) at the specified point and measure the deflection to
confirm that it is within the standard value.
Standard value
V belt deflection : 7~10 mm
2. If the belt deflection is beyond the standard value, adjust the belt tension as follows.
(1) Loosen the bolt adjusting the power steering "V" belt tension.
(2) Put a bar or equivalent between the bracket and the oil pump and adjust the tension so that the belt deflection
is within the standard value.
(3) Tighten the bolt adjusting the power steering "V" belt tension.
(4) Check the belt deflection and adjust it again if necessary.
After turning the V belt in the normal rotation direction more than once, recheck the belt deflection.
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Page 4 of 57
CHECKING POWER STEERING FLUID LEVEL
1. Position the vehicle on a level surface.
2. Start the engine. With the vehicle kept stationary, turn the steering wheel several times continuously to raise the
fluid temperature to 50~60°C (122 to 140°F).
3. With the engine at idle, turn the steering wheel fully clockwise and counterclockwise several times.
4. Make sure there is no foaming or cloudiness in the reservoir fluid.
5. Stop the engine to check for any difference in fluid level between a stationary and a running engine.
1. If the fluid level varies 5 mm (0.2 in.) or more, bleed the system again.
2. If the fluid level suddenly rises after stopping the engine, further bleeding is required.
3. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve,
and lead to decreased durability of the pump
REPLACING POWER STEERING FLUID

1. Jack up the front wheels and support them with rigid racks.
2. Disconnect the return hose from the oil reservoir and plug the oil reservoir.
3. Connect a vinyl hose to the disconnected return hose, and drain the oil into a container.
4. Disconnect the high-tension cable at the ignition coil side.
While operating the starter motor intermittently, turn the steering wheel all the way to the left and then to the right
several times to drain the fluid.
5. Connect the return hose and fix it with a clip securely.
6. Fill the power steering fluid reservoir with the specified fluid.
PSF-3 : 0.9 lit. (0.95 qts.)

Check for fluid leaks from the hose, then stop the engine.
8. Pour the fluid into the bottom of the oil filter in the power steering fluid reservoir.
9. Bleed the air.
AIR BLEEDING
Page 5 of 57
1. Disconnect the ignition coil high tension cable, and then, while operating the starter motor intermittently (for 15 to
20 seconds), turn the steering wheel all the way to the left and then to the right five or six times.
1. During air bleeding, replenish with the fluid so that the level does not fall below the lower position of the
filter.
2. If air bleeding is done while the vehicle is idling, the air will be broken up and absorbed into the fluid.
Be sure to do the bleeding only while cranking.
2. Connect the high tension cable, and then start the engine (idling).
3. Turn the steering wheel to the left and then to the right, until there are no air bubbles in the oil reservoir.
4. Confirm that the fluid is not milky and that the level is between "MAX" and "MIN" marks on the reservoir.
5. Check that there is a little change in the fluid level when the steering wheel is turned left and right.
1. If the fluid level varies 5mm (0.2 in.) or more, bleed the system again.
2. If the fluid level suddenly rises after stopping the engine, further bleeding is required.
3. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve,
and lead to decreased durability of the pump.
OIL PUMP PRESSURE TEST

1. Disconnect the pressure hose from the pump. Connect the special tool between the pump and the pressure hose
as illustrated.
2. Bleed the air, and then start the engine and turn the steering wheel several times so that the fluid temperature can
rise to approximately 50-60°C (122-132°F) operating temperature.
3. Increase the engine speed to 1,000 ± 100 rpm.
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Page 6 of 57
4. Close the shut-off valve of the special tool and measure the fluid pressure to confirm that it is within the standard
value range.
Standard value
Relief pressure :
5.9 MPa (60 kg·cm², 853 psi)
Do not keep the shut-off valve on the pressure gauge closed for more than ten seconds.
5. If the fluid pressure is not within the standard value range, overhaul the oil pump.
6. Remove the special tools, and tighten the pressure hose to the specified torque.
Tightening torque
55~65 Nm (550~650 kg·cm, 40.6~47.9 lb·ft)
Steering System > General Information > Special Service Tools

SPECIAL TOOLS
09517-21400 Removal of pinion gear bearing
Drift
09222-21100 Installation of the pinion gear bearing

Valve stem oil seal installer
09432-21600 Installation of oil pump oil seal.

Bearing installer
09434-14200 Installation of the valve housing oil seal.

Counter shaft bearing installer
09561-11002 Removal of the steering wheel

Steering wheel puller
Page 7 of 57
09565-11100 Measurement of the mainshaft pre-load.
Preload socket
09565-21000 Removal & installation of pinion gear bearing

Pinion bearing remover and and oil seal valve body housing.
installer
09555-21000 Removal & installation of the oil seal from

Bar gear housing.
09565-21100 Removal, installation and adjustment of

Yoke plug torque wrench socket steering gear yoke plug.
09568-34000 Separation of the tie rod end ball joint.

Ball joint
09572-21000 Measurement of the power steering oil

Oil pressure gauge pressure.
(use with 09572-21200, 09572-22100)

Oil pressure gauge adapter pressure.
(Hose side) (use with 09572-21000, 09572-22100)

Oil pressure gaug adapter pressure.
(use with 09572-21000, 09572-21200)
09573-21000 Installation of the oil seal

Oil seal installer guide (use with 09573-21100, 09573-21200,
09517-11000, 09555-21000)
09573-21100 Installation of the back-up washer and oil

Oil seal installer seal
(use with 09573-21000, 09573-21200,
09555-21000)
09573-21200
Oil seal guide
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Page 8 of 57
09573-21200 1. Removal of gear box oil seal and back
Oil seal guide washer. (use with 09555-21000)
2. Installation of gear box oil seal and back
washer. (use with 09555-21000, 09573-
21000).
Steering System > General Information > Troubleshooting

TROUBLESHOOTING (POWERSTEERING)
Excessive play in steering wheel Loose yoke plug Retighten
Loose steering gear mounting bolts Retighten
Loose or worn tie rod end Retighten or replace as necessary
Steering wheel operation is not Drive slippage Check
smooth (Insufficient power assist) Damaged Drive belt Replace
Low fluid level Replenish
Air in the fluid Bleed air
Twisted or damaged hoses Correct the routing or replace
Insufficient oil pump pressure Repair or replace the oil pump
Sticky flow control valve Replace
Excessive internal oil pump leakage Replace the damaged parts
Excessive oil leaks from rack and pinion in Replace the damaged parts
gear box
Distorted or damaged gear box or valve Replace
body seals
Steering wheel does not return Excessive turning resistance of tie-rod end
properly Excessively tightened rack support cover Replace
Inner tie rod and/or ball joint cannot turn Adjust
smoothly Replace
Loose mounting of gear box mounting
bracket Retighten
Worn steering shaft joint and/or body Correct or replace
grommet Replace
Distorted rack Replace
Damaged pinion bearing Reposition or replace
Twisted or damaged hoses Replace
Damaged oil pressure control valve Replace
Damaged oil pump input shaft bearing
Noise Hissing Noise in Steering Gear
There is some noise with all power steering systems.
One of the most common is a hissing sound when the steering wheel is turned
and the car is not moving.This noise will be most evident then turning the wheel
while the brakes are being applied.
There is no relationship between this noise and steering performance.
Do not replace the valve unless the "hissing" noise becomes extreme.
A replaced valve will also make a slight noise, and is not always a solution for
the condition.
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Rattling or chucking noise in the Interference with hoses from vehicle body Reposition
rack and pinion Loose gear box bracket Retighten
Loose tie rod end and/or ball joint Retighten
Worn tie rod and/or ball joint Replace
Noise in the oil pump Low fluid level Replenish
Air in the fluid Bleed air
Loose pump mounting bolts Retighten
A slight "grinding noise" may be heard immediately after the engine is started in extremely cold whether
conditions (below-20°C) : This is due to power steering fluid characteristics in extreme cold conditions and
is not an indication of malfunction.
TROUBLESHOOTING (MANUAL STEERING)

Excessive play in steering wheel Loose rack support cover Retighten
Loose steering gear mounting bolts Retighten
Loose or worn tie-rod end Retighten or replace as necessary
Steering wheel operation is hard Excessive turning resistance of tie-rod ball
Replace
joint
Excessively tightened rack support cover
Adjust
Inner tie rod and/or ball joint cannot turn
Lubricate or replace ball joint
smoothly
Distorted rack
Replace
Worn steering shaft joint and/or body
Replace
grommet
Replace
Damaged pinion bearing
Steering wheel does not return Excessive turning resistance of tie-rod ball
Replace
properly joint
Excessively tightened rack support cover
Adjust
Inner tie rod and/or ball joint cannot turn
Replace
smoothly
Worn steering shaft joint and/or body
Correct or replace
grommet
Replace
Distorted rack
Replace
Damaged pinion bearing
Steering System > General Information > Specifications

SPECIFICATIONS
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Item Specification
Manual steering
Shaft and joint type Collapsible, cross joints (two joints used)
Steering gear type Rack and pinion
Rack stroke 134mm (lock to lock : 3.87 turns)
Power steering
Collapsible, cross joints, tilt column with pop-
Shaft and joint type
up
Steering gear type
Rack and pinion
Rack stroke
134mm (lock to lock : 2.93 turns)
Oil pump type
Vane type
Oil pump displacement
9.6cm³/rev. (0.59 in³/rev.)
Oil pump pressure switch operating pressure
1.5-2.0 MPa (15-20 kg/cm², 213-284 psi)
SERVICE STANDARD
Item Specification
Manual steering
Steering wheel free play 0-30 mm (0-1.1 in.)
Steering angle
Inner wheel 37°37´ ± 1°30´
Outer whel 31°51´
Tie rod end ball joint starting torque 0.5-2.5 Nm (5-25 kg·cm, 0.4-1.8 lb·ft)
Total pinion preload
±180° or less from neutral 0.4-1.1 Nm (4-11 kg·cm, 0.3-0.8 lb·ft)
±180° or more from neutral 0.3-1.6 Nm (3-16 kg·cm, 0.2-1.2 lb·ft)
Tie rod swing resistance 2-5 Nm (20-50 kg·cm, 1.4-3.6 lb·ft)
Power steering
Steering wheel free play
0-30 mm (0-1.1 in.)
Steering angle
Inner wheel
37°37´ ± 1°30´
Outer wheel
31°51´
Stationary steering effort
34.3 N (3.5 kg, 7.8 lbs) or less
Belt deflection [under 98N (10kg, 22lb)
7-10 mm
force]
5.9MPa (60 kg/cm², 853 psi)
Oil pump relief pressure
0.6-1.3 Nm (6-13 kg·cm, 0.4-1.0 lb·ft.)
Total pinion preload
2-5 Nm (20-50 kg·cm, 1.4-3.6 lb·ft)
Tie rod swing resistance
TIGHTENING TORQUE
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Item Nm kg·cm lb·ft
Steering wheel lock nut 35-45 350-450 26-33
Steering column and shaft assembly 13-18 130-180 10-13
mounting bracket 15-20 150-200 11-15
Steering shaft and joint 15-20 150-200 11-15
Pinion gear and joint 4-6 40-60 3-4.4
Dust cover mounting bolt 60-80 600-800 44-59
Gear box mounting bolt 50-55 500-550 37-41
Tie rod end lock nut 16-34 160-340 12-25
Tie rod ball joint slotted nut 50-70 500-700 37-52
Rack yoke plug nut 80-100 800-1000 59-74
Tie rod to rack
Power Steering Only
Valve body housing to rack housing 20-30 200-300 15-22
assembly 8-12 80-120 6-9
Pressure and return tube mounting clip 12-18 120-180 9-13
Pressure and return tube to gear box 20-30 200-300 15-22
Pinion and return valve assembly to self- 50-70 500-700 37-52
locking nut 20-27 200-270 15-20
End plug 25-33 250-330 18-24
Oil pump mounting bracket bolt 55-65 550-650 40.6-47.9
Oil pump adjusting bolt 9-14 90-140 7-10
Pressure hose mounting bolt (to oil 3-5 30-50 2.2-3.6
pump)
Oil reservoir mounting bolt 4-6 40-60 3-4.4
Suction hose mounting clamp
(to oil pump suction connector)
Oil cooler tube mounting bolt
LUBRICANTS
Item Recommended lubricant Quantity
LONG TIME PD2
Horn contact ring of steering wheel As required
(OPTIMOL, GERMAN)
ALVANIA #2 or #3
Bearing of steering shaft As required
(KEUK DONG SHELL, KOREA)
VALIANT R-2 (SHOSEK I,
Ball joint of tie rod end As required
JAPAN)
ONE-LUBER RP
Steering gear housing As required
(KYODOYUSHI, JAPAN)
LONG TIME PD2
Inner ball joint of gear box As required
(OPTIMOL, GERMAN)
Contact area of gear box bellows &
SILICON GREASE As required
tie rod
0.9 liter
Power steering fluid PSF-3 TYPE
(0.5 qts.)
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Steering System > Steering Column & Shaft > Steering Column/Shaft > Components and Components
Location
COMPONENTS
Steering System > Steering Column & Shaft > Steering Column/Shaft > Repair procedures
REMOVAL
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1. Disconnect the (-) negative terminal from the battery.
2. After removing the bolts in the illustration, remove the driver's airbag module.
For the vehicles not equipped with SRS airbag, remove the horn cover
assembly.
4. After aligning the marks on the steering shaft and wheel, remove the steering wheel using the special tool.
Do not hammer on the steering wheel to remove it, doing so may damage the steering column.
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5. After removing the 3 bolts in the illustration, remove the steering column shroud.
6. Remove the connectors of the airbag clock spring and the multifunction switch.
7. Remove the multifunction switch assembly from the steering shaft.
8. After removing 4 connecting bolts, remove the lower crash pad.
9. Remove the 4 bolts fixing the steering column shaft.

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10. Remove the bolt from the universal joint and gear box connecting portion.
11. Remove the steering column shaft assembly.
INSTALLATION
1. Place the steering columnshaft in position and install the 4 mounting bolts temporarily.
2. Install the bolt on the universal joint and gear box connecting part in the driver's side brake pedal lower portion.
• Lock the steering wheel in the straight ahead position to prevent the damage of the clock spring inner
cable when you handle the steering wheel.
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3. Completely tighten the temporarily installed 4 mounting bolts on the steering column shaft.
4. After installing the lower crash pad, tighten the 4 bolts.
5. Install the multi-function switch to the steering column shaft by pushing it until it reashes the marked portion.
6. Install the SRS clock spring and multi-function switch connector.
•When assembling the clock spring, set the center position by setting the marks between the clock spring
and the cover into line. Make an array the mark ( ) by turning the clock spring clockwise to the stop
and then 2.0 revolutions counterclockwise.
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7. After installing the upper/lower column shroud, tighten the 3 bolts.
8. Fix the steering wheel with a lock nut.
9. Fix the SRS module to the steering wheel with 2 bolts.
10. Connect the (-) negative battery cable.
INSPECTION
1. Check the steering column shaft for damage and deformation.
2. Check connections for play, damage and smooth operation.
3. Check the ball joint bearing for wear and damage.
Steering System > Manual Steering System > Manual Steering Gear Box > Components and
Components Location
COMPONENTS
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COMPONENTS
Page 19 of 57
Steering System > Manual Steering System > Manual Steering Gear Box > Repair procedures
REMOVAL
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1. Support the specified point of the vehicle with a lift.
2. Remove the front tires (RH/LH).

3. After removing the split pin, disconnect the tie rod from the knuckle by using the speicial tool.
4. Disconnect the shaft assembly from the gear box inside the passenger compartment.
5. Raise up the vehicle.
6. Remove the manual steering gear box mounting bolt and clamp.
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7. Separate the manual steering gear box assembly by pulling it toward the right side of the vehicle.
INSTALLATION
1. Install the manual steering gear box assembly by inserting it from the right side.
2. Fix the manual steering gear box to the crossmember.
3. Lower the vehicle.
4. Connect the tie rod to the LH/RH knuckles.
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5. Install the tires (LH/RH).
6. Connect the steering shaft assembly to the gear box in the passenger compartment.
DISASSEMBLY
1. Remove the tie rod end from the tie rod.
2. After mounting the tie rod end in a vise, remove the dust cover from the ball joint.
3. Remove the bellows band.

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4. Remove the bellows clip.
5. Pull the bellows out toward the tie rod.
Check for rust on the rack when the bellows are

replaced.
6. Unstake the tab washer which fixes the tie rod and rack with a chisel.
7. Remove the yoke plug lock nut.
8. Remove the yoke plug with a 14mm socket.
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9. Remove the lock nut, yoke plug rack support spring, rack support yoke and bushing.
10. Move the rack completely toward the housing and mount the rack tooth portion in a brass plate of a vise.
At the state of step 11, loosen the tie rod ball joint, then remove the tie rod assembly from the rack.
11. Remove the rack from the gear housing.
Remove the rack toward the left side of the vehicle so as not to damage the bushing by the rack
teeth.
REASSEMBLY
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1. Apply the specified grease to the rack, insert the rack into the gear housing, and then insert the pinion into the
gear housing.
A. Make sure that the rack is inserted into the gear housing from the left side.
B. When inserting the pinion into the gear housing, the pinion gear should be in mesh with the rack gear.
C. Wipe off excessive grease.
2. Prior to oil seal installation in the gear box, apply grease to the surface of the oil seal.
Be sure to use a new oil seal.

3. Install the rack support yoke, rack support spring, yoke plug, and lock nut to the pinion gear box.
4. Tighten the yoke plug to 11Nm (112 kg·cm, 8 lb·ft) and then back off 30°~60°. Secure the yoke plug with the
lock nut.
1. Adjust the yoke plug with the rack in the neutral position.
2. Apply a sealer between the lock nut and the housing.
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5. After installing the tie rod to the rack, punch on a point over the tie rod with a chisel.
6. Install the bellows in position and fix it with the band and clip.
7. Mount tie rod end in a vise and install the dust cover to the tie rod end.
8. Install the tie rod to the tie rod end.
INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY

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When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is fixed
the gear box may be damaged.
TOTAL PINION PRELOAD

1. Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value
0.6~1.3 Nm (6~13 kg·cm, 0.4~1.0 lb·ft)
Measure the pinion preload through the entire stroke of the rack.
2. If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload.
3. If you adjust the yoke plug but do not obtain the total pinion preload, check or replace the yoke plug
components.
TIE ROD SWING RESISTANCE
1. Rotate the tie rod severely ten times.
2. Measure the tie rod swing resistance with a spring scale.
Standard value
2~5 Nm (20~50 kg·cm, 1.4~3.6 lb·ft)
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3. If the measured value exceeds the standard value, replace the tie rod assembly.
Even if the measured value is below the standard value, the tie rod that swings smoothly without excessive
play may be used. If the measured value is below 0.44 kg·cm, replace the tie rod.
BELLOWS INSPECTION
1. Inspect the bellows for damage or deterioration.
2. Make sure the bellows are secured in the correct position.
3. If the bellows are defective, replace them with new ones.
Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Components and
Components Location
COMPONENTS
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COMPONENTS
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Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Repair procedures
REMOVAL
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1. Support the specified portion of the vehicle with a lift.
2. Drain the power steering fluid.

4. After removing the split pin, disconnect the tie rod from the knuckle by using the special tool.
5. Disconnect the steering shaft assembly from the gear box inside the passenger compartment.
7. Loosen the power steering pressure tube mounting clamp and return tube mounting clamp mounting bolt.
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8. Disconnect the pressure tube and return tube fitting from the power steering gear box.
9. Remove the power steering gear box mounting bolt and clamp.
10. Separate the power steering gear box assembly by pulling it toward the rights side of the vehicle.
INSTALLATION
1. Push in the power steering gear box assembly in the right side of the vehicle.
2. Fix the power steering gear box to the crossmember.

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3. Install the pressure tube and return tube fitting to the power steering gear box.
4. Fix the power steering pressure hose and return tube mounting clamp with the bolt.
5. Slowly lower the vehicle.
6. Connect the tie rod to the knuckles (RH/LH)
7. Install the tires (RH/LH)

8. Connect the steering shaft to the driver side gear box.
9. Apply the power steering fluid.

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10. Bleed the air.
DISASSEMBLY
1. Remove the tie rod end from the tie rod.
2. After mounting the tie rod end in a vise, remove the dust cover from the ball joint.
3. Remove the bellows band.
4. Remove the bellows clip.
5. Pull the bellows out toward the tie rod.
Check for rust on the rack when the bellows are

replaced.
6. While moving the rack slowly, drain the fluid from the rack housing.
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7. Unstake the tab washer which fixes the tie rod and rack with a chisel.
8. Remove the tie rod from the rack.
Remove the tie rod from the rack, taking care not to twist the
rack.
9. Remove the yoke plug lock nut.
10. Remove the yoke plug with a 14mm socket.
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11. Remove the lock nut, yoke plug, rack support spring, rack support yoke and bushing from the gear box.
12. Remove the feed tube from the rack housing.
13. Remove the valve body housing by loosening the two bolts.
14. When the end of the circlip comes out of the notched hole of the housing rack cylinder, turn the rack stopper
counterclockwise and remove the circlip.
Be careful not to damage the rack.
15. Remove the rack bushing and rack from the rack housing.
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16. Remove the O-ring from the rack bushing.
17. Remove the oil seal from the rack bushing.
18. Remove the valve body from the valve body housing with a soft hammer.
19. Remove the oil seal and ball bearing from the valve body housing.
20. Remove the oil seal and O-ring from the rack housing.
Be careful not to damage the pinion valve cylinder bore of the rack
housing.
21. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
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When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is fixed,

Standard value
0.6~1.3 Nm (6~13 kg·cm, 0.4~1.0 lb·ft)
3. If not obtain the total pinion preload after adjusting the yoke plug check or replace the yoke plug components.
Standard value
2~5 Nm (20~50 kg·cm, 1.4~3.6 lb·ft)
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BELLOWS INSPECTION
REASSEMBLY
1. Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid : PSF-3
2. Install the oil seal to the specified position in the rack housing.
3. Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid : PSF-3
4. Install the oil seal in the rack bushing.
5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
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6. Apply the specified grease to the rack teeth.
Recommended grease :
Multipurpose grease SAE J310a, NLGI #2 EP
Do not plug the vent hole in the rack with grease.
7. Insert the rack into the rack housing and push in the rack bushing until it is aligned with the notched hole of the
rack housing, then install it.
8. Using a special tool, install the oil seal and the ball bearing in the valve body housing.
9. After applying the specified fluid and grease to the pinion valve assembly, install it in the rack housing assembly.
10. After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly and
O-ring in the gear box.
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11. Install the tie rod and punch on a point over the tie rod with a chisel.
12. Install the bushing, rack support yoke, rack support spring and yoke plug in the order shown in the illustration.
Apply semi-drying sealant to the threaded section of the yoke plug before installation.
13. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to
12 Nm (120 kg·cm, 8.9 lb·ft), with a 14mm socket. Loosen the yoke plug approximately from 30° to 60° and
tighten the yoke nut to the specified torque.
Tightening torque
50~70 Nm (500~700 kg·cm, 37~52 lb·ft)
14. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
15. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Recommended grease : Silicone grease
16. Install the new attaching band to the bellows.
When the bellows are installed, a new band must be

used.
17. Install the bellows in position, taking care not to twist it.
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18. Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip ring
attached in the groove of the tie rod end.
Recommended grease
A : POLY LUB GLY 801K or equivalent
B : SHOWA SUNLIGHT MB2 or equivalent
Dust cover inner side and lip : THREE BOND
19. Install the tie rod to the tie rod end.
20. Check for total pinion preload.

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When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is fixed,

Standard value
0.6~1.3 Nm (6~13 kg·cm, 0.4~1.0 lb·ft)
3. If not obtain the total pinion preload after adjusting the yoke plug check or replace the yoke plug components.
Standard value
2~5 Nm (20~50 kg·cm, 1.4~3.6 lb·ft)
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BELLOWS INSPECTION
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Components and
Components Location
COMPONENTS
Page 45 of 57
Steering System > Hydraulic Power Steering System > Power Steering Hoses > Repair procedures
REMOVAL
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Page 46 of 57
1. Support the specified point of the vehicle with a lift.
2. Drain the power steering fluid.

4. After removing the split pin, disconnect the tie rod from the knuckle using a special tool (09568-34000).
5. Disconnect the shaft assembly from the gear box inside the passenger compartment.
7. Loosen the power steering pressure tube mounting clamp and return tube mounting clamp mounting bolt.
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8. Disconnect the pressure tube and return tube fitting from the power steering gear box.
9. Lower the vehicle and disconnect the pressure hose connector from the oil pump. (When removing the pressure
hose)
10. Disconnect the pressure hose assembly. (When removing the pressure hose)
11. After removing the clip from the color tube, removing the return tube and hose. (When removing the return tube
and hose)
12. Remove the 10mm color tube mounting clip bolt. (When removing the color tube)
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13. Disconnect the remove the color tube from the power steering oil reservoir tank side hose. (When working on
the color tube)
INSTALLATION
1. Support the specified portion of the vehicle with a lift.
2. Insert the color tube from the front pump upper part to the lower part and install 2 mounting bolts.
3. Connect the color tube to the power steering oil reservoir tank side hose, return tube and hose side and fix it with
clips. (When installing the color tube)
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4. Place the pressure hose and tube assembly in position and connect it to the oil pump. (When installing the
pressure hose and tube)
5. Raise the vehicle with a lift.
6. Fix the pressure tube and return tube fitting to the power steering gear box.
7. Fix the power steering pressure tube and return tube mounting clamp with a bolt.
8. Lower the vehicle.
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9. Connect the gear box and steering column shaft universal joint in the passenger compartment.
10. Connect the tie rod end to the LH/RH knuckles.

11. Install the tires (LH/RH).
12. Fill the power steering oil reservoir with fluid.
INSPECTION
1. Twisting the hose by hand, check for cracks.
2. Check that the hose does not contact with other components.
HOW TO FILL WITH POWER STEERING FLUID
1. Fill the power steering reservoir with the power steering fluid to the "Max." position
2. Lift the front wheels with a jack and turn the steering wheel fully to the left and right 5~6 times at 13 rpm, while
driving the pulley only by operating the start motor.
3. Start the engine, let it idle and turn the steering wheel fully left and right several times until bubbles disappear from
the power steering reservoir.
4. If the oil color does not become milk-white and the oil level is constant at the "MAX" position, fluid level is O.K.
If the oil level changes when turning the steering wheel, and the oil overflows when stopping the engine, it
shows that air bleeding wasn't performed perfectly. As it can cause noise and early damage, you must
repeat the above procedures.
Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Components and
Components Location
COMPONENTS
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Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Repair procedures
REMOVAL
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1. Remove the pressure hose from the oil pump.
Disconnect the suction hose from the suction pipe and drain the fluid into a container.
2. Loosen the power steering "V" belt tension adjusting bolt.
3. Remove the "V" belt from the power steering oil pump pulley.
4. After removing the power steering oil pump mounting bolts and the tension adjusting bolt, remove the power
steering oil pump assembly.
5. Remove the power steering oil pump mounting bracket.
INSTALLATION
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1. After installing the oil pump to the oil pump bracket, install the "V" belt and tighten the bolt adjusting tension to the
specified torque.
Standard value
Oil pump adjusting bolt:25~33 Nm (250~330 kg·cm, 18~24 lb·ft)
2. Install the suction hose.
Install the pressure hose to the oil pump, facing the painted part on the hose toward the oil
pump.
3. Install the pressure hose to the oil pump.
Install the pressure hose being careful so that it does not twist and come in contact with other
components.
4. Add power steering fluid (PSF-3).

5. Air bleed the system.
6. Check the oil pump pressure.
DISASSEMBLY
1. After removing the 2 bolts(10mm), remove the suction pipe and the O-ring from the oil pump body.
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2. Loosen the four bolts(12mm) and remove the oil pump cover assembly.
3. Remove the cam ring.
4. Remove the shaft fixing ring using snap ring pliers.
5. Remove the rotor and vanes.
6. Remove the oil pump side plate.

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7. Remove the pulley and shaft assembly from the oil pump body.
8. Remove the oil seal from the oil pump body.
9. Remove the connector(24mm) from the oil pump body, and take out the flow control valve and the flow control
spring.
10. Remove the O-ring from the connector.
Do not disassemble the flow control

valve.
INSPECTION
1. Check the free length of the flow control spring.
Free length of the flow control spring : 36.5mm
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2. Check that the flow control valve is not bent.
3. Check the shaft for wear and damage.
4. Check the V-belt for wear and deterioration.
5. Check the grooves of the rotor and vanes for stratified abrasion.
6. Check the contact surface of the cam ring and vanes for stratified abrasion.
7. Check vanes for damage.
8. Check that there is no striped wear in the side plate or contacting part between the shaft and the pump cover
surface.
REASSEMBLY
1. After installing the O-ring to the connector, install the flow control spring, the flow control valve and the
connector into the pump body.
2. Install the oil seal in the pump body by using the special tool.
3. Install the pulley and shaft assembly to the oil pump body.
4. Install the oil pup side plate and rotor.

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5. After inserting the lock pin into the groove of the front housing, install the cam ring attending to the direction.
6. Install the rotor.

7. Install vanes so that the rounded edges face outward.
8. Install the shaft fixing clip with snap ring pliers.
9. Install the O-ring and oil pump cover assembly.
10. Install the suction pipe and O-ring.
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Page 1 of 30
ACCENT(LC) > 2005 > G 1.5 SOHC > Suspension System
Suspension System > General Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and Name) Use Illustration
09216-21100 Removal & installation of lower arm bushing
Mount bushing remover (G)
(use with 09216-21200, 09545-02000)
09216-21200 Removal & installation of the lower arm

Mount bushing remover and bushing (G)
installer base (use with 09216-21100, 09545-02000)
09532-11600 Measurement of the lower arm ball joint and

Preload socket stabilizer link starting torque
09545-02000 Installation of the lower arm ball joint

Lower arm bushing remover and
installer
09545-21100 Installation of the lower arm ball joint snap

Ball joint dust cover installer ring
09545-25000 Removal & installation of the lower arm

Lower arm bushing remover and bushing (A)
installer
09551-25000 Removal & installation of the trailing arm

Trailing arm bushing remover and bushing
installer
09552-25000 Removal & installation of the rear suspension

Rear suspension arm remover arm bushing
and installer
09568-34000 Separation of the lower arm ball joint

Ball joint puller
Page 2 of 30
A-20 Compression of the rear coil spring
Strut compressor adapter (use with J38402)
A-42 Compression of the front coil spring

A-50 Compression of the rear coil spring

J38402 Compression of the front & rear coil spring

Strut spring compressor (use with A-42 or A-20)
09545-11000 (A,B) Installation of the front lower arm ball joint

Ball joint remover and installer
09545-3A000 Removal of lower arm bushing

Lower arm bushing remover
Suspension System > General Information > Troubleshooting

TROUBLESHOOTING
Hard steering Improper front wheel alignment Correct
Excessive turning resistance of lower arm ball joint Replace
Low tire pressure Adjust
No power assist Repair and replace
Poor return of steering wheel to
Improper front wheel alignment Correct
center
Poor rough ride Improper front wheel alignment Correct
Malfunctioning shock absorber Repair or replace
Broken or worn stabilizer Replace
Broken or worn coil spring Replace
Worn lower arm bushing Replace the lower arm
assembly
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Page 3 of 30
Abnormal tire wear Improper front wheel alignment Correct
Improper tire pressure Adjust
Malfunctioning shock absorber Replace
Wandering Improper front wheel alignment Correct
Poor turning resistnace of lower arm ball joint Repair
Loose or worn lower arm bushing Retighten or replace
Vehicle pulls to one side Improper front wheel alignment Correct
Excessive turning resistance of lower arm ball joint Replace
Bent lower arm Repair
Steering wheel shimmy Improper front wheel alignment Correct
Poor turning resistance of lower arm ball joint Replace
Broken or worn stabilizer Replace
Worn lower arm bushing Replace
Bottoming Broken or worn coil spring Replace
WHEEL AND TIRE DIAGNOSIS

Rapid wear at the center Rapid wear at both shoulders Wear at one shoulder
• Center- tread down to fabric due • Underinflated tires • Toe adjustment out of
to excessive over inflated tires • Worn suspension components specification
• Lack of rotation • Excessive cornering speeds • Camber out of specification
• Excessive toe on drive wheels • Lack of rotation • Damaged strut
• Heavy acceleration on drive • Damaged lower arm
WHEEL AND TIRE DIAGNOSIS

Partial wear Feather edges wheels Wear pattern
• Cansed by irreqular burrs on • Toe adjustment out of • Excessive toe on non-drive

brak drums. specification wheels
• Damaged or worn tie rods • Lack of rotation
• Damaged knuckle
Page 4 of 30
Suspension System > General Information > Specifications
SPECIFICATIONS
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Page 5 of 30
SERVICE STANDARD
Standard value Front Rear
Toe-in mm(in.) 0 ± 3 (0 ± 0.12) 3 ± 2 (0.12 ± 0.0787)
Camber 0 ± 30´ -41´ ± 30´
Caster 1°48´ ± 30´
King pin inclination angle 11°03´ ± 30´
King pin offset mm(in.) 5.8 (0.23)
Steel wheel
Wheel runout Aluminum wheel
0.6mm (0.028 in.) :
Radial 0.3mm (0.012 in.)
Average of LH & RH
Axial 0.3mm (0.012 in.)
0.8mm (0.032 in.)
TIGHTENING TORQUE
Page 6 of 30
Items Nm kgf·cm lbf·ft
Castle nut
Strut upper installation nut *
Strut assembly to knuckle
Front strut mounting self locking
nut 220 ~ 260 2200 ~ 2600 162 ~ 192
Lower arm ball joint to knuckle 20 ~ 30 200 ~ 300 14 ~ 22
Lower arm/lower arm bracket 75 ~ 90 750 ~ 900 55 ~ 66
mounting bolt 60 ~ 70 600 ~ 700 43 ~ 51
Tie rod end ball joint to knuckle 60 ~ 72 600 ~ 720 43 ~ 52
Rear roll stopper to sub-frame 95 ~ 120 950 ~ 1200 69 ~ 87
bolt 15 ~ 34 150 ~ 340 11 ~ 25
Rear roll stopper mounting nut 30 ~ 40 300 ~ 400 22 ~ 29
Rear strut mounting self locking 45 ~ 60 450 ~ 600 33 ~ 44
nut 45 ~ 50 450 ~ 500 33 ~ 37
Rear stabilizer link to stabilizer 35 ~ 45 350 ~ 450 26 ~ 33
bar 17 ~ 26 170 ~ 260 13 ~ 19
Rear stabilizer bar bracket bolt 130 ~ 150 1300 ~ 1500 96 ~ 110
Rear suspsension arm (A,B) to 100 ~ 120 1000 ~ 1200 74 ~ 88
axle carrier 80 ~ 100 800 ~ 1000 59 ~ 74
Rear suspension arm (A) to 130 ~ 150 1300 ~ 1500 96 ~ 110
body frame * 100 ~ 120 1000 ~ 1200 74 ~ 88
Rear suspension arm (B) to 40 ~ 50 400 ~ 500 30 ~ 37
body frame *
Trailing arm to axle carrier nut *
Trailing arm to bracket nut
Trailing bracket to body frame
• Replace the self-locking nuts with new ones after removal.

• '*' parts should be temporarily tightened, and then fully tighted with the vehicle on the ground in an unladen
condition.
LUBRICANTS
Location Recommended lubricant Quantity
In ball joint of lower arm Variant R-2 grease or poly lub gly 801 K As required
SAE J310a, Chassis grease (NLGI No. 0 or
In insulator bearing strut As required
equivalent)
In rear statilizer link case Lubchem SB 6042M or Sunlight MB2 As required
Suspension System > Front Suspension System > Front Strut Assembly > Components and
Components Location
COMPONENTS
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Page 7 of 30
Suspension System > Front Suspension System > Front Strut Assembly > Repair procedures
REMOVAL
1. Remove the front wheel.
Page 8 of 30
2. Detach the brake hose bracket from the strut assembly.
Do not pry or force the components excessively.
3. Remove the strut upper mounting nuts(3).
4. Remove the strut lower kunckle mounting bolts(2).
5. Remove the strut assembly.

DISASSEMBLY
1. Remove the insulator dust cover with a flat-tip screw driver.
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Page 9 of 30
2. Using the special tool(J38402), compress the coil spring until there is only a little tension on the strut.
Do not use an impact gun.
3. Remove the lock-nut at the top end of the shock absorber.

4. Remove the strut insulator, spring seat assembly, coil spring and strut dust cover.
INSPECTION
1. Check the strut insulator bearing for wear or damage.
2. Check the rubber parts (Insulator dust cover, Strut insulator, Spring seat assembly, Strut dust cover, Spring
lower pad) for damage or deterioration.
3. Check the coil spring for sagging and weakness.
4. Reassemble all the parts except for the coil spring.
5. Repeat pushing and pulling of the damper assembly as shown.
6. Check for smooth operation through a full stroke.
If there is no compression, no extension and the gas is leaking, it is strongly recommended that the damaper
should be replaced.
REASSEMBLY
Page 10 of 30
1. Install the spring lower pad with the protrusions fitted in the holes of the spring lower seat.
2. Install the strut dust cover on the shock absorber.

3. Using special tool(J38402, A-42), compress the coil spring.
After the spring is fully compressed, install it on the shock absorber.
Install the coil spring with the identification color mark facing toward the
knuckle.
4. After fully extending the piston rod, install the spring seat assembly and the strut insulator.
Align the D-shaped hole in the spring seat assembly with the indentation on the piston
rod.
5. After having correctly seated the upper and lower ends of the coil spring in the upper and lower spring seat
grooves, install the new self-lockingnut but do not tighten it.
6. Remove the special tool (J38402, A-42).

7. Tighten the self-locking nut to the specified torque.
Tightening torque
60~70 Nm (600~700 kgf·cm, 43~51 lbf·ft)
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Page 11 of 30
8. Pack grease in the strut insulatior bearing and install the insulator dust cover.
Make sure that no grease is on the insulator rubber. (see page SS-3)
Suspension System > Front Suspension System > Front Lower Arm > Components and Components
Location
COMPONENTS
Page 12 of 30
Suspension System > Front Suspension System > Front Lower Arm > Repair procedures
REMOVAL
1. Remove the front wheel and tire.
2. Remove the split pin, the castle nut and the washer.
3. Loosen the lower arm ball joint nut, but do not remove it.
4. Remove the strut lower mounting bolts(2).
5. Push the axle hub outward to disconnect the drive shaft from the axle hub.
6. Using the special tool(09568-34000), disconnect the lower arm ball joint from the lower arm.
7. Install the strut lower mounting bolt temporarily.

8. Remove the stabilizer link nut.
9. Remove the lower arm bushing (A) and bushing (G) mounting bolts(2).
10. Remove the lower arm assembly.
INSTALLATION
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Page 13 of 30
1. First, fix the lower arm bushing (G) and then bolt up slightly.
2. It would be better to insert the driveshaft spline and the ball joint in the knuckle nearly at the same time.
3. Install the stabilizer link in the lower arm assembly the moment the driveshaft is inserted gradually.
Do not, however, tighten the self-locking nut in this step.
4. Push the brake disc and hub inward in order to assemble the lower arm bushing (A) to the front chassis.
5. Tighten the lower arm bushing (A) bolt.
6. Tighten the lower arm bushing (G) bolt completely.
7. After fixing the stabilizer link using 14mm spanner, tighten the self-locking nut.
8. Assemble the washer, castle nut and split pin.

9. Install the wheel and tire.
REPLACEMENT
BALL JOINT AND DUST COVER REPLACEMENT
1. Using a screwdriver, remove the dust cover from the lower arm ball joint.
2. Remove the snap ring.

Page 14 of 30
3. Using a plastic hammer, disconnect the ball joint from the lower arm.
Hammering with the special tool (09545-3A000) placed under the lower arm as shown may prevent the
deformation of the lower arm.
4. Using the special tool (09545-11000), press the ball joint into the lower arm assembly.
Unless it it pressed firmly, the snap ring will not fit perfectly to the groove.
5. Install the snap ring.

6. If there is not sufficient grease on the ball joint assembly, apply grease abundantly.
7. Using the special tool (09545-21100), install the dust cover. The special tool will make the installation process
even easier.
LOWER ARM BUSHING (A) REPLACEMENT

1. Install the special tool (09545-25000) and the lower arm on the press-machine.
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Page 15 of 30
2. Remove the bushing (A).
3. Apply soap solution to the following parts.

A. Outer surface of the new bushing (A).
B. Inner surface of the lower arm bushing mount (B).
4. Install the new bushing onto the lower arm by using special tool.
5. Center the bushing by using by the following procedure, if necessary.
A. Reset the special tool and lower arm.
B. Center the bushing.
After centering the bushing, wipe off the soap solution.
LOWER ARM BUSHING (G) REPLACEMENT

1. Install the special tool (09216-21100, 09216-21200, 09545-02000) and the lower arm.
2. Press out the bushing (G).
3. Apply soap solution to the following parts.
A. Outer surface of the bushing.
B. Inner surface of the lower arm bushing mount.
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4. Install the new bushing onto the lower arm by using special tool (09216-21100, 09216-21200, 09545-02000).
INSPECTION
1. Check the bushing for wear and deterioration.
2. Check the lower arm for bending or breakage.
3. Check the ball joint dust cover for cracks.
4. Check all bolts.
5. Check the lower arm ball joint for rotating torque.
A. If a crack is noted in the dust cover, replace the ball joint assembly.
B. Shake the ball joint stud several times. (see page SS-12)
C. Measure the balll joint rotating torque.
Standard value
2.5~9 Nm (25~90 kgf·cm, 1.8~6.6 lbf·ft)
D. If the rotating torque exceeds the upper limit of the standard value, replace the ball joint assembly.
E. Even if the rotating torque is below the lower limit of the standard value, the ball joint may be reused, unless it
has drag and excessive play.
Suspension System > Front Suspension System > Front Stabilizer Bar > Components and Components
Location
COMPONENTS
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Page 17 of 30
Suspension System > Front Suspension System > Front Stabilizer Bar > Repair procedures
REMOVAL
1. Remove the front wheel.
2. Remove the stabilizer link assembly.
3. Remove the stabilizer bracket and bushing.

Page 18 of 30
5. Remove the stabilizer bar.
INSTALLATION
1. Install the bushing onto the stabilizer bar.
2. Align the bracket with the bushing.
Make sure the projections are securely in the space of the bracket.
3. Using the access opening, temporarily tighten the bushing fixtures then position the bushing on the opposite side.
4. Secure the stabilizer link with a open-end wrench (14 mm) then install the self locking nut.
INSPECTION
1. Check the stabilizer bar for deterioration and damage.
2. Check all bolts for condition and straightness.
3. Check the stabilizer link dust cover for cracks or damage.
4. Check the stabilizer link ball joint rotating torque.
A. If there is a crack in the dust cover, replace it and add grease.

B. Shake the stabilizer link ball joint stud several times.
C. Mount the self-locking nut on the ball joint, and then measure the ball jointrotating torque.
Standard value
1.7~3.2 Nm (17~32 kgf·cm, 1.3~2.4 lbf·ft)
D. If the rotating torque exceeds the upper limit of the standard value, replacethe stabilizer link.
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Page 19 of 30
E. Even if the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless it
Suspension System > Rear Suspension System > Rear Strut Assembly > Components and Components
Location
COMPONENTS
Suspension System > Rear Suspension System > Rear Strut Assembly > Repair procedures
Page 20 of 30
REMOVAL
1. Fold down the rear seat back assembly.
2. Remove the speaker trim and the luggage side trim.
3. Remove the rear strut upper mounting nuts(3).
4. Remove the wheel and tire.

5. Disconnect the brake hose and wheel speed sensor wiring from the rear strut.
6. Remove the strut and carrier mounting bolts(2).
Be careful not to drop the rear strut.
7. Remove the rear strut assembly.
DISASSEMBLY
1. Using the special tool (A-20, A-50, J38402), compress the coil spring until there is only a little tension on the
strut.
Do not use an impact gun.
2. Remove the nut at the top end of the shock absorber.

3. Remove the spring upper seat, coil spring, dust cover and strut assembly.
INSPECTION
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Page 21 of 30
1. Check the insulator for wear or damage.
2. Check the rubber parts for damage or deterioration.
3. Check the coil spring for sagging and weakness.
4. Check the shock absorber for abnornal resistance or unusual sounds.
REASSEMBLY
1. Install the lower spring pad so that the protrusions fit through the holes in the spring lower seat.
2. Install the dust cover on the shock absorber.

3. Using the special tool (A-20, A-50, J38402), compress the coil spring.
After spring is fully compressed, install it on the shock absorber.
4. After fully extending the piston rod, install the spring seat and insulator assembly.
Align the D-shaped hole in the spring seat upper assembly with the indentationon the piston
rod.
Page 22 of 30
5. After having correctly seated the upper and lower ends of the coil spring in the upper and lower spring seat
grooves, fully install the new self-lockingnut but do not tighten.
6. Position the bolt of the spring seat to align with the projection of the pad as shown in the illustration.
7. Remove the special tool.

8. Tighten the self-locking nut to the specified torque.
Tightening torque
40~55 Nm (400~550 kgf·cm, 29.5~40.6 lbf·ft)
Suspension System > Rear Suspension System > Rear Suspension Arm > Repair procedures
REPLACEMENT
REAR SUSPENSION ARM (A,B) BUSH REPLACEMENT
1. Install the special tool (09552-25000) and the suspension arm on a press.
2. Press out the bushing.

3. Apply soap solution to the new bushing and suspension arm.
4. Using the special tool (09552-25000), press fit the bushing.
Suspension System > Rear Suspension System > Upper Arm, Lower Arm And Assist Link >
COMPONETS
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Page 23 of 30
Suspension System > Rear Suspension System > Trailing Arm > Repair procedures
REPLACEMENT
TRAILING ARM BUSH REPLACEMENT
Page 24 of 30
1. Install the special tool(09551-25000) and the trailing arm on a press.
2. Press out the bushing.

3. Apply soap solution to the new bushing and the trailing arm bushing mount.
4. Position the projection of the bushing in a line as shown in the illustration.
5. Using the special tool (09551-25000), press fit the bushing.
Suspension System > Rear Suspension System > Rear Stabilizer Bar > Repair procedures
REPLACEMENT
REAR STABILIZER BAR REPLACEMENT
1. Remove the stabilizer bar and link assembly.
2. Check the stabilizer link ball joint rotating torque.
A. If there is a crack in the dust cover, replace it and add grease. (see page SS-4)
B. Shake the stabilizer link ball joint stud several times.
C. Mount the self-locking nut on the ball joint, and then measure the ball joint rotating torque.
Standard value
0.3~1.0 Nm (3~10 kgf·cm, 0.22~0.73 lbf·ft)
D. If the rotating torque exceeds the upper limit of the standard value, replace the stabilizer link.
E. Even if the rotating torque is below the lower limit of the standard value,the ball joint may be reused unless it
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Page 25 of 30
3. Install the stabilizer link lower mounting nut so that the distance (A) is at the standard value.
: 4~6 mm (0.157~0.236 in.)
4. Identification mark of the stabilizer bar must be positioned to the left vehicle mounting.
Suspension System > Tires/Wheels > Tire > Repair procedures

TIRE
TIRE WEAR
1. Measure the tread depth of the tires.
Tread depth of tire [Limit] : 1.6mm (0.06 in.)
2. If the remaining tread depth is less than the limit, replace the tire.
When the tread depth of the tires is less than 1.6 mm (0.06 in.) the wear indicators will
appear.
TIRE ROTATION
The temporary spare tire should not used in the wheel rotation.
CHECKING FOR PULL AND WANDER

Page 26 of 30
1. Switch the front right and front left tires, and perform the road test inorder to confirm vehicle statility.
2. If the steering pulls to opposite side, switch the front and rear tires, and again perform the road test.
3. If the steering continues to pull to one side, switch the front right and left tires again, and again perform the road
test.
4. If the steering continues to pull to the opposite side, replace the front wheels with new ones.
TIRE CHAINS AND SNOW TIRES

1. Use tire chains only on the front wheels. Do not use tire chains on rear wheels.
2. When using snow tires, use them on all four wheels for maneuverability and safety.
Suspension System > Tires/Wheels > Wheel > Repair procedures

FRONT WHEEL ALIGNMENT
TOE-IN
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Page 27 of 30
Standard value
Toe-in (B-A): 0±3 mm (0±0.12 in.)
Description Toe changes mm (in.)/deg.

No. of turns of tie rod (Same 1/2 Approx. 5.5(0.217)/32.5´
amount for right and left) 1 Approx. 11(0.433)/1°
• Toe-in adjustment should be made by turning the right and left tie rods by the same amount.
• When adjusting toe-in, loosen the outer bellows clip to prevent twisting the bellows.
• After the adjustment, tighten the tie rod end lock nuts firmly and reinstall the bellows clip.
Tightening torque
Tie rod end lock nuts:
50~55 Nm (500~550 kgf·cm, 36~40 lbf·ft)
CAMBER
Standard value
Front camber: 0° ± 30´
CASTER
Standard value
Front caster: 1°48´ ± 30´
Page 28 of 30
REAR WHEEL ALIGNMENT

TOE-IN
Standard value
Rear toe-in: 3 ± 2mm (0.12 ± 0.079 in.)
• Release parking brake for the better measurement.

• The rear suspension arm (B) mounting bolt should be turned an equal amount on both sides when adjusting.
Inside of the vehicle: toe-in

Outside of the vehicle: toe-out
The scale has graduations of approximately 2.4 mm (0.09 in.)
(single side toe angle quivalent to 14´)
The eccentric bolt should be adjusted within a 90° range left and rightfrom the center position.
CAMBER
Standard value
Rear camber: -41´ ± 30´
Rear camber is also pre-set at factory and can not be adjusted.

If the camber measured is not within the standard value below, replace the bent or dmaged parts.
WHEEL RUNOUT
1. Jack up a vehicle and support it with a jack stand.
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Page 29 of 30
2. Measure the wheel runout with a dial indicator as illustrated.
3. Replace the wheel if the wheel runout exceeds the limit. (refer to 'SERVICE STANDARD'. see page SS-p.3)
Wheel runout [Limit]

Steel wheel
- Radial : 0.6mm (0.028 in.) : Average of LH & RH)
- Axial : 0.8mm (0.032 in.)
Aluminum wheel
- Radial : 0.3mm (0.012 in.)
- Axial : 0.3mm (0.012 in.)
WHEEL NUT TIGHTENING

1. Tightening torque.
Steel and aluminum alloy wheel.
Specified torque
90~110 Nm (900~1,100 kgf·cm, 65~80 lbf·ft)
When using an impact gun, final tightening torque should be checked using a torque wrench.
Page 30 of 30
2. Tightening order.
Go around the wheel tightening every other nut until they are all tight.
Then double-check each nut for tightness.
INSTRUCTIONS FOR ALUMINUM TYPE WHEELS

1. Aluminum is vulnerable to alkalies. If the vehicle has been exposed to automobilewashing detergent, or salt from
sea water, or road chemicals, rinse the vehicleas soon as possible. Then apply wax to the wheels to prevent
corrosion.
2. When steam cleaning the vehicle, do not direct the steam onto the aluminumwheels.
When tightening nuts for aluminum wheels, observe the following :
(1) Clean the hub surface.
(2) After finger-tightening the wheel nuts, tighten to specifications.
(3) Do not use an impact gun or push the wrench by foot to tighten the wheel nuts.
(4) Do not apply oil to the threaded portions.
Suspension System > Tires/Wheels > Repair procedures

WHEEL & TIRE BALANCE
1. Dynamic imbalance of wheel & tire assy should not exceed AL wheel : 40g, STEEL wheel : 60g per bead seat
before balancing.
2. After balancing dynamic imbalance, balance weight should not exceed AL wheel : 80g, STEEL wheel : 100g per
wheel & tire assy except andit M/C addition work.
3. Balance weight must not over 1 for each side of except additional balancing with andit M/C.
4. In case balance weight positions concord each other, attach them side by side.
In case imbalance at andit M/C, balance following table.
Unbalance per bead seat Balance weight
0 ~ 7.5g
No balancing work
7.6 ~ 12.5g
10g
12.6 ~ 17.5g
15g
17.6 ~ 27.5g
20g
27.6g ~
Discompose wheel and tire
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Page 1 of 24

ACCENT(LC) > 2005 > G 1.5 SOHC > General Information

General Information > General Information > General Information

IDENTIFICATION NUMBER DESCRIPTION

ENGINE IDENTIFICATION NUMBER

AIR BAG WARNING / CAUTION LABEL

AIR BAG WARNING / CAUTION LABEL (CONT'D)

WARNING / CAUTION LABEL (CON'T)

Detach connector before unmounting. Assemble strictly according to manual instructions.

D : PASSENGER MODULE CAUTION

E : SUPPLEMENTAL RESTRAINT SYSTEM

EMISSION CONTROL LABEL

TIGHTENING TORQUE TABLE OF STANDARD PARTS

Bolt nominal Torque Nm (kg.cm, lb.ft)

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

Always use Genuine Hyundai parts and recommedended fluid.

SELECTION OF ENGINE OIL

Depending on their location.

RUBBER PARTS AND TUBES

MEASURING BODY DIMENSIONS

MEASURING ACTUAL DIMENSIONS

CHECKING CABLES AND WIRES

SERVICING THE ELECTRICAL SYSTEM

PRECAUTIONS FOR CATALYTIC CONVERTER

09452-21002 Measurement of the oil pressure

09452-21500 Measurement of the oil pressure

J28467-B Removal and installation of transaxle

J28467-125 Use with J28467-B

SPECIAL TOOLS (M/T)

J28467-125 Use with J28467-B

Automatic Transaxle System > General Information > Troubleshooting

PROBLEM CHART (M/T)

Automatic Transaxle System > General Information > Specifications

TIGHTENING TORUQE (A/T)

SERVICE SPECIFICATIONS (M/T)

TIGHTENING TORQUE (M/T)

HYDRAULIC CONTROL SYSTEM

Items A4AF2 A4AF3

• The 2nd. pressure is supplied to SA through CSV.

- F/C, SR : from 2-3/4-3 shift valve

2. TCM fail when drive with 1st or 2nd speed.

• SA : Servo Apply pressure

2. Removal the air cleaner.

3. Remove the transaxle range switch connector.

5. Remove the cotter pin of the control cable.

6. Remove the oil filler tube.

7. Remove the clip of the control cable.

8. Remove the oil cooler hose.

10. Remove the u-joint.

11. Remove the power steering return hose.

18. Remove the transaxle side cover.

23. Remove the front roll stopper.

24. Remove the rear roll stopper.

26. Remove the bell housing cover. (Bolts : 5EA)

27. Remove the torque converter mounting plate bolts (3EA).

28. Remove the cylinder block plate bolt.

29. Install the jack for supporting transaxle.

30. Remove the lower mounting bolts (2EA) of the transaxle.

2. Install the transaxle control cable and adjust as follows: